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] This invention is related to a device to detect a malfunction of a componnet of a fuel supply module and a method therof.

Background of the invention
[0002] Conventionally, there has been a technique of detecting a differential pressure between a pressure on an entrance side of a fuel filter and a pressure on an exit side of the fuel filter, and calculating a fuel flow rate in a fuel pump after the fuel passes through the fuel filter, whereby a clogging degree of the fuel filter is calculated based on the difference of pressures on either side of the filter and the flow rate in the fuel pump.

[0003] A WO patent 2020097202 discloses systems and methods determine a filter efficiency of a fluid filter. A characteristic of fluid flow of a fluid is monitored at a first point and at a second point on a flow path of a fluid filter. A particle absorption level of the fluid filter is determined that is a difference in the characteristic of the fluid flow at the first point and the second point. The particle absorption level of the fluid filter is at a particle absorption saturation level based on the difference in the characteristic of the fluid flow at the first point and the second point. The particle absorption saturation level is an indicator that the particles retained by the fluid filter is decreased and replacement of the fluid filter is required to increase the particles retained by the fluid filter to be above the particle absorption saturation level.

Brief description of the accompanying drawings
[0004] Figure 1 illustrates a device for detecting a malfunction in a fuel supply module, in accordance with an embodiment of the invention; and
[0005] Figure 2 illustrates a flowchart for a method of detecting a malfunction of a component of the fuel supply module in accordance with the present invention.

Detailed description of the embodiments
[0006] Figure 1 illustrates a device for detecting a malfunction of a component in a fuel supply module, in accordance with an embodiment of the invention. The fuel supply module 12 comprises a fuel strainer 14 and a fuel pump 16 positioned inside a fuel tank 18, an auxiliary filter 20 and a control unit 22 adapted to control at least one operation of the component 11 of the fuel supply module 12. The fuel supply module 12 comprises the device 10 having at least one sensing element 24 and at least one flow meter 26 positioned in proximity to the fuel pump 16 and in fluid communication with the fuel pump 16 and the fuel strainer 14, such that, the at least one sensing element 24 and the at least one flow meter 26 adapted to detect a change in a parameter related to the fuel supply module 12 during an operational state of the fuel supply module 12.

[0007] Further the components of the fuel supply module 12 and the working of the components of the fuel supply module 12 is explained in detail. The fuel is filled into the fuel tank 18 at a fuel station such that, the fuel strainer 14 and a part of the fuel pump 16 will be immersed into the fuel that is filled in the fuel tank 18. The fuel pump 16 will be pumping the fuel from the fuel tank 18 into an engine of the vehicle. During this operational state, the fuel will be made to flow from the fuel strainer 14 and the auxiliary filter 20 and will be filtered before getting delivered into the engine. Due to the impurities present in the fuel, the fuel strainer 14 and the auxiliary filter 20 will be clogged and not the enough amount of fuel will be pumped via the fuel pump 16 during the operational state of the fuel supply module 12.

[0008] Due to the insufficiency of the fuel to pump, the fuel pump 16 experience a dry run condition, where the pump 16 will be operated without the fuel being pumped. Due to this dry run condition, the fuel pump 16 will be damaged and will be deteriorated in a faster way. And also, due to the heat produced from the fuel pump 16, there will a safety hazard of burning of the fuel in the fuel tank 18. The present invention provides solution to the above mentioned via the arrangement of flow meter 26 and the pressure sensing element 24 positioned in proximity to the fuel pump 16 and fuel strainer 14.

[0009] With the parameters detected, the control unit 22 detects the level of clog of the fuel strainer 14 and the working state of the fuel pump 16. The parameter of fuel supply module 12 is chosen any one of the parameters chosen from a suction pressure of a fuel and a flow rate which is a number of rotations per second of the flow meter 26. The component 11 of the fuel supply module 12 is chosen from anyone of the following components comprising the fuel pump 16 and the fuel strainer 14. The at least one sensing element 24 is a pressure sensing element adapted to sense the suction pressure value of the fuel flowing from the fuel strainer 14 into the fuel pump 16. The at least one flow meter 26 measures the flow rate (the number of rotations per second) based on the flow of the fuel from the fuel strainer 14 to the fuel pump 16.

[0010] According to one embodiment of the invention, the device 10 comprises two sets (24(a) &26(a) / (24(b) &26(b)) of the sensing element 24 and the flow meters 26. A first set (24(a) &26(a)) comprises a first sensing element 24(a) and a first flow meter 26(a) and a second set (24(b) &26(b)) comprising a second sensing element 24(b) and a second flow meter 26(b). The first set (24(a) &26(a)) of sensing element 24(a) and the flow meter 26(a) is positioned between the fuel strainer 14 and an inlet 28 of the fuel pump 16 in the fuel tank 20 and the second set (24(b) &26(b)) of the sensing element 26(b) and the flow meter 26(b) is positioned between an outlet 30 of the fuel pump 20 and the auxiliary fuel filter 22. According to one embodiment of the invention, the at least one flow meter 26(a/b) is a turbine which provides the flow rate (the number of rotations per second value), when the fuel is made to flow via the at least one flow meter 26(a/b).

[0011] The control unit 22 is chosen from a group of control units comprising a microprocessor, a microcontroller, a digital circuit, an integrated chip and the like. The control unit 22 stores a set of predefined values of the suction pressures of the first sensing element 24(a) and the second sensing element 24(b) during a calibration process. In addition to that, the control unit 22 further stores the predefined values of the first flow meter 26(a) and the second flow meter 26(b)in the form of a flow rate i.e., a number of rotations per second. The control unit 22 compares these predefined values with the real time detected values during the operational state of the fuel supply module 12.

[0012] Figure 2 illustrates a method of detecting a malfunction in at least one component 11 of a fuel supply module 12. The fuel supply module 12 comprises a fuel strainer 14 and a fuel pump 16 positioned inside a fuel tank 18, an auxiliary filter 20, a control unit 22. The fuel supply module 12 comprises the device 10 having at least one sensing element 24 and at least one flow meter 26. In step S1, the fuel tank 18 is filled with fuel and the fuel is filtered through the fuel strainer 14 and the auxiliary filter 20. In step S2, the fuel is pumped from the fuel supply module 12 using the fuel pump 16. In step S3, a suction pressure of the fuel is detected that is flowing from the fuel strainer 14 into the fuel pump 16 via at least one sensing element 24.

[0013] In step S4, a number of rotations per second value of the at least one flow meter 26 is detected when the fuel flows from the fuel strainer 14 to the fuel pump 16. In step S5, the detected suction pressure and the number of rotations per second from the at least one sensing element 24 and the at least one flow meter 26 is compared with the predefined values. In step S6, the malfunction in the fuel supply module 12 is detected based on the comparison result.

[0014] The above method is explained in detail. When the fuel is filled in the fuel tank 18 in the fuel filling station, the fuel strainer 14 filters the impurities from the filled fuel and the fuel pump 16 supplies the filtered fuel to the engine unit of the vehicle. The fuel is further filtered via the auxiliary filter 20 before getting injected into the engine unit. Due to the impurities present in the fuel, the fuel strainer 14 will be clogged and the required amount of fuel will not be delivered to the fuel pump 16. In order to identify this, the first set (24(a) &26(a)) of sensing element 24(a) and the flow meter 26(a) is positioned between the inlet of the fuel pump 16 and the fuel strainer 14. The sensing element 24 and flow meter 26 are connected to the control unit 22 for detecting the malfunction of the component 11 of the fuel supply module and for monitoring the health of the fuel strainer 14 and the fuel pump 16. The control unit 22 detects the clogging of the fuel strainer 14 and the deterioration in the fuel pump 16 based on the detected results from the fuel strainer 14 and the fuel pump 16.

[0015] The suction pressure of the fuel will be detected using the first sensing element 24(a) and the flow rate (which is number of rotations per second) is detected using the first flow meter 26(a). The same is transmitted to the control unit 22. The control unit 22 further compares the detected values with the predefined values, and if there is a variation in the detected values, the control unit 22 determines the malfunction in the fuel strainer 14 of the fuel supply module 12. The malfunction will be the level of clog present in the fuel strainer 14.

[0016] The second set (24(b) &26(b)) of the sensing element 24 and the flow meter 26 is positioned between the outlet 30 of the fuel pump 16 and the auxiliary filter 20. When the fuel from the fuel strainer 14 flows into the fuel pump 16 and then via the auxiliary filter 20, the control unit 22 receives the detected values of the pressure of the fuel flowing out of the fuel pump 16 from the pressure sensing element 24 and the flow rate of the fuel from the flow meter 26, which is the number of rotations per second. If the fuel strainer 14 is clogged, then there will be a pressure drop in the fuel flowing into and out of the fuel pump 16. The control unit 22 compares the detected values received from the inlet side 28 and the outlet side 30 of the fuel pump 16 with the predefined values. Based on the comparison result, the control unit 22 detects the malfunction either in the fuel pump 16 or fuel strainer 14.

[0017] The control unit 22 detects the malfunction in the fuel strainer 14 based on outputs rom the first set(24(a) &26(a)) and in the fuel pump 16 based on outputs from the first set (24(a) &26(a)) and the second set(24(b) &26(b)). The malfunction in the fuel strainer 14 and the fuel pump 16 is detected when the outputs from the first set(24(a) &26(a)) and the second set(24(b) &26(b)) is compared with corresponding predefined values. The output of the comparison result discloses the level of clog in the fuel strainer 14 or any damage in the fuel pump 16.

[0018] If the second sensing element 24(b) and second flow meter 26(b) detected values are varied from the predefined values, then the control unit 22 detects a high current flow flowing to the fuel pump 16 and the same is displayed in the vehicle dashboard.ie, If the second sensing element 24(b) and second flow meter 26(b) detected values are higher than the predefined values, then the control unit 22 detects the malfunction in the fuel pump 16 and the same is displayed in the vehicle dashboard.

[0019] If the first set and second set of sensing element 24 and the flow meter 26 detected values are less than from the predefined values, then the control unit 22 checks for the current value passing through the fuel pump 16 to confirm the running state of the fuel pump 16. If the values detected are maintained lower than the predefined values over the period of time and the pump current being constant, then the control unit 22 identifies as the dry run condition of the fuel pump 16 and activates the limp home mode.
The same information is provided to the user in the dashboard of the vehicle using any one of the alerting means like a buzzer, a sound, a light, an alarm and the like. During this condition, the control unit 22 activates a limp home mode in the vehicle, for safe parking of the vehicle to a nearest service center or to a safe place.

[0020] With the above disclosed device, the user of the vehicle easily identifies the fault/malfunctioning of the specific component in the fuel supply module 12. The wear and tear of the fuel pump 16, fuel strainer 14 can be easily identified or detected based on the method disclosed above. the device 10 further avoids the dry run condition of the fuel pump 16, by detecting the malfunction in the fuel supply module 12 within the time frame. The above method provides a low-cost effective solution when compared to the conventional one’s available in the market.

[0021] 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
, Claims:We Claim:

1. A device (10) for detecting a malfunction of a component (11) in a fuel supply module (12), said fuel supply module (12) comprises a fuel strainer (14) and a fuel pump (16) positioned inside a fuel tank (18), an auxiliary filter (20), a control unit (22) adapted to control at least one operation of said component (11) of said fuel supply module (12);
characterized in that:
said device (10) comprising:
- at least one sensing element (24) and at least one flow meter (26) positioned in proximity to said fuel pump (16) and in fluid communication with said fuel pump (16) and said fuel strainer (14), such that, said at least one sensing element (24) and said at least one flow meter (26) adapted to detect a change in a parameter related to said fuel supply module (12) during an operational state of said fuel supply module (12).

2. The device (10) as claimed in claim 1, wherein said parameter of said fuel supply module (12) is any one of the parameters chosen from a suction pressure of a fuel and a flow rate (a number of rotations per second of said flow meter (26) ) and wherein said component (11) of said fuel supply module (12) is chosen from anyone of the following components comprising said fuel pump (16) and said fuel strainer (14).

3. The device (10) as claimed in claim 2, wherein said at least one sensing element (24) is a pressure sensing element adapted to sense said pressure value of said fuel flowing from said fuel strainer (14) into said fuel pump (16).

4. The device (10) as claimed in claim 2, wherein said at least one flow meter (26) adapted to measure said flow rate (said number of rotations per second) based on the flow of said fuel from said fuel strainer (14) to said fuel pump (16).

5. The device(10) as claimed in claim 1, wherein said device(10) comprises two sets (24(a) &26(a) /24(b) & 26(b)) of said sensing element (24) and said flow meters (26), a first set (24(a) &26(a) ) comprises a first sensing element (24(a)) and a first flow meter (26(a)), a second set (24(b) &26(b)) comprising a second sensing element (24(b)) and a second flow meter (26(b)).

6. The device (10) as claimed in claim 6, wherein said first set (24(a) &26(a)) is positioned between an inlet (28) of said fuel pump (16) and said fuel strainer (14) and said second set (24(b) &26(b)) is positioned between an outlet (30) of said fuel pump (16) and said auxiliary fuel filter (20).

7. The device (10) as claimed in claim 1, wherein said at least one flow meter (26(a/b)) is a turbine adapted to provide said flow rate based on said number of rotations per second value, when the fuel is made to flow via said at least one flow meter (26(a/b)).

8. The device (10) as claimed in claim 1, wherein said control unit (22) adapted to detect said malfunction in said fuel strainer (14) based on outputs rom said first set (24(a) &26(a) ) and said control unit (22) adapted to detect said malfunction in said fuel pump (16) based on outputs from said first set(24(a) &26(a) ) and said second set(24(b) &26(b) ).

9. The device (10) as claimed in claim 8, wherein said malfunction in said fuel strainer (14) and said fuel pump (16) is detected when said outputs from said first set (24(a) &26(a)) and said second set(24(b) &26(b)) is compared with corresponding predefined values.

10. A method of detecting a malfunction in at least one component (11) of a fuel supply module (12), said fuel supply module (12) comprising a fuel strainer (14) and a fuel pump (16) positioned inside a fuel tank (18), an auxiliary filter (20), a control unit (22), a device (10) comprising at least one sensing element (24) and at least one flow meter (26);
said method comprising:
- filling said fuel tank (18) with fuel and filtering said fuel through said fuel strainer (14) and said auxiliary filter (20);
- pumping said fuel from said fuel supply module (12) using said fuel pump (16);
characterized in that:
- detecting a suction pressure of said fuel flowing from said fuel strainer (14) into said fuel pump (16) via at least one sensing element (24);
- detecting a flow rate (a number of rotations per second value) of said at least one flow meter (26) when said fuel flowing from said fuel strainer (14) to said fuel pump (16);
- comparing said detected suction pressure and said flow rate (said number of rotations per second) from said at least one sensing element (24) and said at least one flow meter (26);
- detecting said malfunction in said fuel supply module (12) based on said comparison result.