Claims:We Claim

1. Fuel level indicating and tilt responsive fuel cut-off system (100) for a motor vehicle comprising of a base plate (5), a segmented housing (10), a first set of connector points (15), a set of wiring harness (20), a float (35), a float attachment arm (40), a non-metallic block (45), a segmented resistive material strip (50), a roller (55), a roller holding bracket (60), a spring (65), a third set of connector points (68), a set of fastening means (70), a metallic pendulum (25), a second set of connector points (28), and a set of metallic contact plates (30)
wherein,
- the segmented housing (10) has at least two segments (10A and 10B) connected along a plane (13) in a manner such that openings (10AH and 10BH) of the segments (10A and 10B) are orthogonal with respect to each other, the segment (10B) is positioned and fixed at the center of the base plate (5) in a manner that base plate (5) is at an inclination (?) with respect to a vertical plane (X-X) passing through the centers of both segments (10A and 10B);
- the first set of connectors points (15) having at least two separate connectors points (15A and 15B) that are provided on the base plate (5) at a position immediately below the segment (10B) of the housing (10), the connecting wires (20) have at least two connecting wire sub sets (20A and 20B) that are respectively linked with said connector points (15A and 15B) below the base plate (5);
- the segment (10A) is positioned above and connected with the segment (10B) along the plane (13) through the third set of connector points (68), the segment (10A) has a support wall (10ASW) with at least two support projections (10AP1 and 10AP2) along the same vertical plane (X-X) with the projection (10AP1) being located above the support projection (10AP2), the support projection (AP1) has a hollow cylindrical shape which allows it to receive one end of the Z-shaped the float arm (40) within itself, the outer surface of the projection (10AP1) supports the non-metallic block (45);
- the segmented resistive material strip (50) is attached to the base of the non-metallic block (45) in a manner such that the reference axis (Y-Y) of said segmented resistive material strip (50) is offset by an angle (?) with respect to a reference axis (Z-Z) of the roller (65);
- the float arm (40) is connected to the non-metallic block (45) through the fastening means (70) so as to permit the non-metallic block (45) to move in tandem with the float arm (40), the other end of the float arm (40) is connected to the float (35);
- the roller holding bracket (60) has a cylindrical base (60B) and a U-shaped head portion (60HP), said cylindrical base (60B) is supported on the projection (10AP2) and the lower end of the cylindrical base (60B) is restricted by a fastening means (70); the spring (65) is positioned concentrically with the cylindrical base (60B) so as to be located between the projection (10AP2) and the U-shaped head portion (60HP); and the U-shaped head portion (60HP) supports the roller (65) so as to enable it to stay in contact with the segmented resistive material strip (50);
- the segmented resistive material strip (50) and the roller (65) are configured to connect the wiring sub set (20B) through a connector point (15B) and said connector point (15B) is in communication with the segmented resistive material strip (50) and said roller (65) through links (80) provided into the support walls (10ASW and 10BSW);
- the metallic pendulum (25) is positioned on a projection (10BP) given on its support wall (10BSW) and the set of metallic contact plates (30) are positioned on the support wall (10BSW) at the same level as the projection (10BP) and at equal separation from the projection (10BP) so as to permit a base section (25B) of the metallic pendulum (25) from coming into contact with the set of metallic contact plates (30) when the metallic pendulum (25) swings by an angle (ß) along the projection (10BP);
- the metallic pendulum (25) and the set of metallic contact plates (30) are in communication with the processing unit (printed circuit board) (33) through the links (27) provided within the support wall (10BSW); and
- the processing unit (33) is positioned on the connector points (28) given at the base of the segment (10B) and said connector points (28) in turn are in communication with the wiring harness sub set (20A) through the connector point (15A).

2. The fuel level indicating and tilt responsive fuel cut-off system (100) as claimed in claim 1, wherein covers (73 and 75) are fitted on the openings (10AH and 10BH) respectively of the segments (10A and 10B) of the housing (10).

3. The fuel level indicating and tilt responsive fuel cut-off system (100) as claimed in claim 2, wherein
- the segment (10B) is positioned and fixed at the center of the base plate (5) in a manner that base plate (5) is at an inclination (?) with respect to a vertical plane (X-X) passing through the centers of both segments (10A and 10B) and the said inclination (?) being in the range of 10 to 30 degree; and
- the base plate (5) is positioned and fixed on the bottom of the fuel tank within the fuel tank of a motor vehicle by the set of fastening means (70).

4. The fuel level indicating and tilt responsive fuel cut-off system (100) as claimed in claim 3, wherein
- the set of metallic contact plates (30) and the projection (10BP) are so positioned on the support wall (10BSW) of the segment (10B) that the contact plates permit the metallic pendulum (25) to swing by an angle (ß) and the angle (ß) is in the range of -60 to +60 degree with tolerance of 5 degree; and
- the base section (25B) of the metallic pendulum (25) is configured to have at least two flat surfaces (25BA and 25BB) on its opposite ends to facilitate the positive contact along a wide surface with the set of metallic contact plates (30).

5. The fuel level indicating and tilt responsive fuel cut-off system (100) as claimed in claim 4, wherein the segmented resistive material strip (50) is attached to the base of the non-metallic block (45) in a manner such that the reference axis (Y-Y) of said segmented resistive material strip (50) is offset by an angle (?) with respect to a reference axis (Z-Z) of the roller (65) and the said angle (?) is in the range 5 to 15 degree.

Dated this 30th day of March 2022

Sahastrarashmi Pund
Head – IPR
Endurance Technologies Ltd.

To,
The Controller of Patents,
The Patent Office, at Mumbai.
, Description: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 INDICATING AND TILT RESPONSIVE FUEL CUT-OFF SYSTEM FOR A MOTOR 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 relates to systems that are provided for sensing the fuel level and rollover/extreme tilting in two wheeled motor vehicles. It more particularly relates to an electro mechanical comprehensive system comprising fuel level indicating unit and tilt responsive fuel cut-off unit for a vehicles.

Background of the Invention

[002] The fuel level sensing system provided in motor vehicles ordinarily utilize 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 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. As there are very few other options that can be cheaply and efficiently utilized to perform the same function as that of the contact needle, this wearing out of resistive material from the track is considered as ordinary wear and tear that is to be dealt with by replacing the sensing system if the sensing system ever stops functioning. Even though other systems for sensing fuel level form part of the state of the art, this setup for sensing fuel level is still widely utilized as it is much easier to measure change in fuel level in terms of change of resistance in an electric circuit, than it is by any other existing means.

[003] In addition to the fuel level sensing system, for enhancing safety, rollover/extreme tilt sensing system is also provided on motor vehicles. Most effective conventional rollover/tilt sensing system use a combination of semicircular magnet(s) mounted on a shaft, a sensor for sensing change in polarity and an ECU. The semicircular magnet(s) mounted on the shaft are capable of moving in response to tilting of the vehicle and it is this movement that can be sensed by a sensor capable of sensing change in polarity. The sensor output, processed by the ECU is transmitted to safety mechanisms which terminate fuel flow, disconnect the battery and execute any other protective actions when the sensed rollover/extreme tilt indicates the possibility of an accident having occurred. As correct sensing of rollover/extreme tilt is dependent on correct sensing of change in magnetic polarity, this assembly has to be manufactured very accurately for it to work correctly in all circumstances. As accurate manufacturing is hard to achieve in all instances, there exists a finite possibility that this system may not sense all instances of rollover/extreme tilt accurately. This technical necessity of manufacturing it accurately for it to be functional at all makes it a relatively costly protective system to provide in a motor vehicle.

[004] As providing both of these systems can enhance vehicle user’s convenience and safety, providing both of them in a single package that performs each of its functions properly and without suffering from any of the described limitations, has been felt necessary for a long period of time.

Objectives of the Present Invention

[005] The main object of the present invention is to provide a fuel level indicating and tilt responsive fuel cut-off system for vehicles.

[006] Another objective of the present invention is to provide a fuel level indicating and tilt responsive fuel cut-off system for vehicles that is quite compact, durable and has an extremely long life that eliminates the need of repairing or changing it during lifetime of the vehicle.

[007] Yet another objective of the present invention is to provide a fuel level indicating and tilt responsive fuel cut-off system for vehicles that can be depended upon to predictably perform its function when there is an accident.

Brief Description of Drawings

[008] This invention is illustrated in the accompanying drawings, throughout which like reference letters 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

[009] Figures 1a, 1b and 1c discloses different views of a fuel level indicating and tilt responsive fuel cut-off system as an integrated module in accordance with the present invention.

[0010] Figures 2a, 2b, 2c, 2d and 2e shows different views of fuel level indicating unit of the integrated system as per the present invention.

[0011] Figures 3a and 3b shows different views of tilt responsive fuel cut-off unit of the integrated system in accordance with the present invention.

[0012] Figures 4a and 4b shows the different positions (centrally suspended and tilted) of the metallic pendulum of the tilt responsive fuel cut-off unit in the integrated system in accordance with the present invention.

[0013] Figures 5a and 5b discloses cut sectional views of the fuel level indicating and tilt responsive fuel cut-off system from different sides in accordance with the present invention.

Detailed Description of the Present Invention

[0014] 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.

[0015] The preferred embodiment of fuel level indicating and tilt responsive fuel cut-off system (100), which overcomes the discussed limitations of existing systems, comprises of a base plate (5), a segmented housing (10), a first set of connector points (15), a set of wiring harness (20), a float (35), a float attachment arm (40), a non-metallic block (45), a segmented resistive material strip (50), a roller (55), a roller holding bracket (60), a spring (65), a third set of connector points (68), a set of fastening means (70), a metallic pendulum (25), a second set of connector points (28), and a set of metallic contact plates (30).

[0016] In fuel level indicating and tilt responsive fuel cut-off system (100) (refer Figs. 1a to 1c), the segmented housing (10) has at least two segments (10A and 10B) connected along a plane (13) in a manner such that openings (10AH and 10BH) of the segments (10A and 10B) are orthogonal with respect to each other. The covers (73 and 75) are respectively fitted on the openings (10AH and 10BH) of the segments (10A and 10B) of the housing (10). The segment (10B) is positioned and fixed at the center of the base plate (5) in a manner that base plate (5) is at an inclination (?) with respect to a vertical plane (X-X) passing through the centers of both segments (10A and 10B), and the said inclination (?) is in the range of 10 to 30 degree depending on the geometry of the fuel tank. The base plate (5) is positioned and fixed on the bottom of the fuel tank within the fuel tank of a motor vehicle by the set of fastening means (70). The first set of connectors points (15) having at least two separate connectors points (15A and 15B) that are provided on the base plate (5) at a position immediately below the segment (10B) of the housing (10). The connecting wires (20) have at least two connecting wire sub sets (20A and 20B) that are respectively linked with said connector points (15A and 15B) below the base plate (5).

[0017] The segment (10A) is positioned above and connected with the segment (10B) along the plane (13) through the third set of connector points (68), the segment (10A) has a support wall (10ASW) with at least two support projections (10AP1 and 10AP2) along the same vertical plane (X-X) with the projection (10AP1) being located above the support projection (10AP2), the support projection (AP1) has a hollow cylindrical shape which allows it to receive one end of the Z-shaped the float arm (40) within itself, the outer surface of the projection (10AP1) supports the non-metallic block (45). The segmented resistive material strip (50) is attached to the base of the non-metallic block (45) in a manner such that the reference axis (Y-Y) of said segmented resistive material strip (50) is offset by an angle (?) with respect to a reference axis (Z-Z) of the roller (65) (refer Figs 2d and 2e), and the said angle (?) is in the range 5 to 15 degree.

[0018] The float arm (40) is connected to the non-metallic block (45) through the fastening means (70) so as to permit the non-metallic block (45) to move in tandem with the float arm (40), the other end of the float arm (40) is connected to the float (35). The roller holding bracket (60) has a cylindrical base (60B) and a U-shaped head portion (60HP). The cylindrical base (60B) is supported on the projection (10AP2) and the lower end of the cylindrical base (60B) is restricted by a fastening means (70). The spring (65) is positioned concentrically with the cylindrical base (60B) so as to be located between the projection (10AP2) and the U-shaped head portion (60HP). The U-shaped head portion (60HP) supports the roller (65) so as to enable it to stay in contact with the segmented resistive material strip (50). The segmented resistive material strip (50) and the roller (65) are configured to connect the wiring harness sub set (20B) through a connector point (15B), with said connector point (15B) being in communication with the segmented resistive material strip (50) and said roller (65) through links (80) provided into the support walls (10ASW and 10BSW).

[0019] When the fuel is filled during operation of the vehicle, the float (35) rises, this thereby rotates the non-metallic block (45) connected with the float (35) through the float arm (40) in an anti-clockwise direction on the projection (10AP1) (refer Figs. 2a to 2c). The segmented resistive material strip (50) attached on the non-metallic block (45) thereby also rotates and moves in the same direction along the projection (10AP1). This causes the roller (65) to roll over segments provided over the segmented resistive material strip (50) and hence cause a change in the value of resistance in the electric circuit connected with wiring harness sub set (20B). This change is reflected on a display unit provided for the user on a display panel, as a rise in fuel level inside the fuel tank. Alternatively, when the amount of fuel in the fuel tank goes down, the float (35) falls, the non-metallic block (45) connected with the float (35) through the float arm (40) now rotates in a clockwise direction on the projection (10AP1) (refer Fig. 2a to 2d). The segmented resistive material strip (50) attached on the non-metallic block (45) thereby also rotates and moves in the same direction along the projection (10AP1). This again causes the roller (65) to roll back over segments provided over the segmented resistive material strip (50), and hence cause a change in the value of resistance in the electric circuit connected with wiring harness sub set (20B). This change is reflected on a display unit provided for the user on a display panel, as a fall in the level of fuel inside the fuel tank.

[0020] As the segmented resistive material strip (50) is offset by an angle (?) with respect to the roller (65), the roller (65) comes in contact with only one segment of the segmented resistive material strip (50) at any single instant in time. This allows for clearly defined and precise transition from resistance value to another, thereby allowing the change of level of fuel to be indicated with great degree of precision and redundancy. Sometimes there are likely chances that the roller (65) comes in contact with more than one segment of the segmented resistive material strip (50). In this scenario, the resistance value of extreme (last) segment will get sensed to show the fuel level. For example, the roller is in contact with segments c, d and e, then the resistance value of segment e will be considered. The disclosed range of the angle (?) is therefore significant as it identifies the range in which the degree of precision is the most optimum. As the element in contact with the segmented resistive material strip (50) is the roller (65), the wearing of the segmented resistive material strip (50) is also reduced.

[0021] Furthermore, the roller (65) supported on the roller holding bracket (60) can not only rotate, but also move vertically downwards/upwards to cause compression/expansion of the spring (65) positioned concentrically with the cylindrical base (60B) and located between the projection (10AP2) and the U-shaped head portion (60HP) (refer Fig. 5b). This action prevents the roller (65) from exerting excessive pressure on the segmented resistive material strip (50) when the non-metallic block (45) is rotating clockwise or anticlockwise direction on the projection (10AP1). This thereby enhances the life of the fuel level indicating and tilt responsive fuel cut-off system (100).

[0022] The metallic pendulum (25) (refer Figs. 3a, 5a and 5b) is positioned on a projection (10BP) given on its support wall (10BSW) and the set of metallic contact plates (30) are positioned on the support wall (10BSW) at the same level as the projection (10BP) and at equal separation from the projection (10BP) so as to permit a base section (25B) of the metallic pendulum (25) from coming into contact with the set of metallic contact plates (30) when the metallic pendulum (25) swings by an angle (ß) along the projection (10BP). The set of metallic contact plates (30) and the projection (10BP) are so positioned on the support wall (10BSW) of the segment (10B) that the contact plates permit the metallic pendulum (25) to swing by an angle (ß), with the angle (ß) being in the range of -60 to +60 degree with 5O tolerance. The base section (25B) of the metallic pendulum (25) is configured to have at least two flat surfaces (25BA and 25BB) on its opposite ends to facilitate the positive contact along a wide surface with the set of metallic contact plates (30). The metallic pendulum (25) and the set of metallic contact plates (30) are in communication with the processing unit (printed circuit board) (33) through the links (27) provided within the support wall (10BSW). The processing unit (33) is positioned on the connector points (28) given at the base of the segment (10B) and said connector points (28) in turn are in communication with the wiring harness sub set (20A) through the connector point (15A).

[0023] In the event of an accident, when the vehicle has over turned or is lying on its side, the pendulum (25) swings along the axis of the projection (10BP), moving by an angle (ß) in either clockwise or anticlockwise depending upon the orientation in which the vehicle is tilting, and establishes contact with the metallic contact plate (30). Hence the disclosed limit for angle (ß) is significant because it decides the condition in which an accident could be stated to have happened. This change is sensed by the processing unit (printed circuit board) (33), which then through the connector points (28) given at the base of the segment (10B), sends a signal through the connector point (15A) and the wiring harness sub set (20A) to cause, fuel supply cut-off to the engine, disconnection of the battery power and execute any other protective actions as the devices attached with the vehicle permit. As the segment (10B) is positioned and fixed at the center of the base plate (5) in a manner that base plate (5) is at an inclination (?) with respect to a vertical plane (X-X) passing through the centers of both segments (10A and 10B), the fuel level indicating and tilt responsive fuel cut-off system (100) can hence be attached at any surface at a commensurate inclination (?). Care is taken to install the fuel level indicating and tilt responsive fuel cut-off system (100) in such a manner that the axis of the projection (10BP) remains coaxial or parallel to the possible direction of rolling/tilting of the vehicle.

[0024] The fuel level indicating and tilt responsive fuel cut-off system (100) in accordance with the disclosed embodiment provides the following technical advantages that contributes to the advancement of technology:
- It provides a reliable fuel level indicating and tilt responsive fuel cut-off system for vehicles.
- It provides system that is very durable and has an extremely long life that eliminates the need of repairing or changing it during lifetime of the vehicle.
- It provides a system that can be depended upon to predictably perform its function when there is an accident.
- It provides a system that is capable of differentiating between any two closely resembling operating conditions indicating the level of fuel present inside the fuel tank.
- Ease of assembly as two distinct unit are now provided in a single module in the same time which originally was required for the one unit only, leading to reduced cycle time and improvement in production output.
- Conducting copper wire is common till PCB solder point, thus reduction in cost and at the same time effective space management within the fuel tank of a vehicle.
- Single wiring harness is required for connecting the two units in a single module which reduces complexity of wiring harness, reduction in the wiring harness requirement and cost of overall harness design leading the design of invention very simple and easy to handle.
- The cleverly packaged module of fuel level indicating and tilt responsive fuel cut-off system placed inside the fuel tank, isolates it from external intended or unintended damage leading to enhancement in the life of a system.

[0025] The disclosed invention hence overcomes the limitation of the systems forming state of the art. As would be clear to a person skilled in the art, the contact points, the connector points, the fastening means, and the wiring harness can be easily changed in the described invention without changing the overall construction and working of the invention. Therefore any change pertaining to them must not be construed to be taking a resulting system out of the scope of the claimed invention. 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.