Technical Field
Present disclosure relates in general to two wheeled vehicles. In particular, the present disclosure relates to a fuel tank cap assembly in two wheeled vehicles.
Background
In general, a two-wheeler vehicle run by petroleum fuel has a fuel tank to store and supply fuel to a power generation unit such as an engine. The fuel tank is required to be provided with a cap that closes a refill opening of the fuel tank. The cap is removably secured on the fuel tank to allow opening and closing of the refill opening required for refilling the fuel tank. In the hinged type caps for fuel tank, the cap is hinged proximate to the refill opening.
Proper operation of the fuel tank cap is necessary for safe operation of a vehicle. The cap is required to be open only while refilling and is required to be closed at all other times such as while the vehicle is stationary or moving. Riding the vehicle with fuel tank cap in open condition may pose a serious hazard. To overcome such situations, a sensor assembly is generally provided on the vehicles. The sensor assembly facilitates detecting the open or closed condition of the fuel tank cap and indicate the condition of the cap to the user or to an electronic control unit of the vehicle. Based on the signal, the operation of the vehicle may be disabled by corresponding configuration in the ECU or the user may be signaled to close the fuel tank cap before operating the vehicle.
The sensor assembly may have any known type of position sensor such as a hall sensor. The sensor detects presence of fuel tank or any part thereof within the proximity of the sensor, for example within 1 mm from the sensor.

If the fuel tank or any part thereof is detected within the predetermined proximity, the position is detected as closed, and otherwise detected as open.
In conventional fuel tank cap assemblies, in which the cap is hinged to the fuel tank, the sensor for detecting open or closed position of the fuel tank cap is mounted on a boss or a mounting bracket made of sheet metal which is permanently hinged to the fuel tank. The sensor is generally welded on the boss or the bracket. Such arrangement of the sensor requires more effort and time during assembly or manufacturing process, as the bracket or boss hinged to the fuel tank is prone to misalignment due to hinged movement of the bracket during the mounting process.
Further, as the sensor is mounted on a movable component, the positioning or alignment of the sensor may change in course of usage of the fuel tank cap, and the sensor may give false readings due to the misalignment. For example, in a fuel tank cap assembly, the sensor is aligned and configured so as to indicate a closed position of the cap when the fuel tank is detected within 1 mm from the sensor. In such assembly, repeated usage over a period of time may make the components of the assembly fall out of the alignment, and the fuel tank may keep out of 1 mm distance from the sensor during a closed position of the cap. In such instance, the sensor will signal the condition of the cap as open and the ignition may fail to switch on due to false determination of position of fuel cap, or the sensor may generate a false fuel cap open signal. The present disclosure is directed to address one or more problems as discussed above, or other related problems in the conventional fuel tank cap assemblies.
Summary
Present disclosure provides for a fuel tank cap assembly wherein the sensor for detecting position of the fuel tank cap is placed on the fuel tank

of the vehicle. Further, the fuel tank cap is hinged to the fuel tank using an arm configured to be placed proximate to the sensor when the fuel tank cap is in a closed position. The assembly as disclosed herein is easy to manufacture and more reliable.
Brief Description of Drawings
FIG. 1 illustrates a perspective view of the fuel tank cap assembly in
accordance with an embodiment.
FIG. 2 illustrates a cross-sectional view of the fuel tank cap assembly of
FIG. 1, with the cap in a closed position.
FIG. 3 illustrates a sectional view of the fuel tank cap assembly of FIG. 1,
with the cap in a open position.
Description
A fuel tank cap assembly, hereinafter referred to as the assembly (10), is disclosed. The assembly (10) has a cap (12) and a base (14). The cap (12) has a curved hinge arm, hereinafter referred to as the arm (16). The cap is hinged to the base (14) using a hinge pin (15) that hinges arm (16) of the cap (12) with the base (14). The cap is configured to move or pivot between an open position and a closed position. FIG. 1 and FIG. 2 illustrate the assembly (10) with the cap (12) in the closed position. Whereas, FIG. 3 illustrates the assembly (10) with the cap (12) in the open position. The cap (12) may have other required features as known in the art. For example, a breather valve, a lock, etc. as required.
The base (14) is configured for a rigid attachment to the fuel tank (not shown) of the vehicle. The base (14) has a peripheral wall (18) and a cover (20). The peripheral wall is substantially cylindrical in shape. The cover (20) is in form of a circular ring shaped plate aligned horizontally and is placed on an upper circular edge of the peripheral wall (18) to at least partially conceal peripheral wall (18) and other components of the assembly (10)

that are mounted in close proximity with the peripheral wall (18) of the base, as described later, in order to maintain aesthetical appeal of assembly. The cover (20) is not shown in FIG. 3 for simplicity. The circular opening defined by the peripheral wall (18) and the cover are aligned to provide an inlet for fuel in the fuel tank through the assembly (10).
Further, the peripheral wall (18) is adapted for attachment of the base (14) to the fuel tank. The base may be attached to the fuel tank using any suitable means such by welding or by using fasteners, etc.
A sensor (26) is mounted on the base (14). The sensor may be any suitable position sensor known in the art. The base (14) has a first bracket (22) and a second bracket (24), both extending radially outward from the peripheral wall (18) of the base (14). The first bracket (22) is configured to support the sensor (26) to sense position of the cap (12) of the fuel tank. As shown in FIGS. 1-3, the sensor (26) is mounted in a cavity (28) defined in the first bracket (22). The first bracket (22) may be adapted to house and securely support the sensor (26) as required. In the embodiment as illustrated, the first bracket (22) is formed to desired shape to house and support the sensor (26). In an embodiment, the first bracket (22) may be of any other suitable shape and size depending on the shape and size of the sensor (26). Suitable provisions may be provided for mounting and securing the sensor (26) on the first bracket (22). For example, the sensor (26) may be mounted using a snap lock engagement with provisions of groove and protrusions provided on body of the sensor (26) and on the first bracket (22). In an alternate embodiment, screws or bolts may be used to secure the sensor (26) on the first bracket (22). Yet in an embodiment, the sensor (26) may be press fitted in the cavity (28) defined by the first bracket (22). Any other suitable method may be used.

The second bracket (24) extends radially outward from the peripheral wall (18) and is configured for supporting a locking mechanism (30) that locks the cap (12) in closed position. As shown, the first bracket (22) may be placed opposite to the second bracket (24). The locking mechanism (30) and its components are shown as an example only. The locking mechanism has a lever (34) and a cable (36) for actuation of the lever (34) to open the cap or move the cap (12) to the open position. The base (14) may have other provisions as required.
The cap (12) is hinged to the base (14) by hinging the arm (16) with the base as shown in FIG. 2 and FIG. 3. The arm is in curved shape to limit the pivotal or rotary movement of the cap (12) relative to the base (14). The arm (16) is shown as integral with the cap in the embodiment as illustrated. A portion of the arm (16) abuts the base (14) or the cover (20) once the cap (12) is moved by a predefined angle to the fully open condition.
The sensor (26) is positioned on the bracket such that when the cap (12) moves towards the closed position, a portion of the arm (16) approaches the sensor (26) mounted on the first bracket (22). When the cap reaches in the closed position, the arm (16) actuates the sensor (26) to trigger a signal indicating closed position of the cap (12). The placement of the sensor (26) and the design of the arm (16) are configured such that the arm (16) actuates the sensor (26) only on reaching the closed position. Further, as the cap (12) is moved from closed position towards the open position, the arm (16) moves away from the sensor (26) and the sensor (26) indicates the open position of the cap (12).
In the embodiment as shown, the sensor shown is an electrical switch sensor. The sensor (26) has a button (32) that gets actuated due to movement of the arm (16). The button (32) gets toggled by the arm (16). When the cap reaches to the closed position, the button gets pressed by

the arm (16). Pressing the button may lead to completing or breaking the circuit in the electrical sensor to signal the open or close position of the cap (12). The sensor (26) is configured such that press of the button (32) indicates closed position of the fuel tank cap (12). Further, as the cap (12) moves to open position, the button (32) is released and the sensor (26) indicates the open position of the cap (12). In FIG. 3, the sensor (26) is not shown for illustrating the cavity (28) for mounting the sensor (26). It may be understood that any suitable sensor may be used for detection of position of the cap (12). For example, in an embodiment, any other suitable position or proximity sensor, such as a hall-sensor, may be used.
Further, the sensor (26) may be provided with suitable provisions for connection to the electrical circuit or other electrical or electronic components on the vehicle. For example, in the embodiment as shown, the sensor (26) has connectors (34) for connection to a controller.
In the embodiment as illustrated, the arm (16) is illustrated as substantially U-shaped. It may be understood that the shape of the arm (16) may be altered based on relative position of the sensor (26) and the arm (16) of the cap (12).
Placement of the sensor (26) on the base (14), provides for ease of manufacturing as the sensor (26) may be placed before or after the attachment of the base (14) to the fuel tank. Therefore, the assembly (10) including the base (14) and the cap (12) may be pre-assembled and installed on the fuel tank as a complete assembly (10). Moreover, the assembly (10) as disclosed herein also provides for a more reliable and maintainable assembly (10) as the relative position and coupling of the base (14) and cap (12) maintains the alignment and can be easily repaired or replaced by removing the base (14) and the cap (12).

WE CLAIM:
1. A fuel tank cap assembly (10) comprising:
a base (14);
a cap (12) hinged to the base (14), the cap (12) configured to move between an open position and a closed position;
a sensor (26) mounted on the base (14), the sensor (26) configured to determine the open or the closed position of the cap (12);
wherein the cap (12) hinged to be base (14) by a hinge arm (16) extending from the cap (12), the hinge arm (16) configured to actuate the sensor (26) for determination of the open or the closed position of the cap (12).
2. The fuel tank cap assembly (10) as claimed in claim 1, wherein the sensor (26) has a button (32), and the hinge arm (16) toggles the button (32) to indicate the closed or the open position of the cap (12).
3. The fuel tank cap assembly (10) as claimed in claim 1, wherein the base (14) comprises a peripheral wall (18) and a first bracket (22) extending from the peripheral wall (18), the sensor (26) mounted on the first bracket (22).
4. The fuel tank cap assembly (10) as claimed in claim 1, wherein the sensor (26) is an electrical switch sensor.
5. The fuel tank cap assembly (10) as claimed in claim 1, wherein the sensor (26) is a magnetic sensor.
6. The fuel tank cap assembly (10) as claimed in claim 1, wherein the hinge arm (16) is a U-shaped arm.

7. The fuel tank cap assembly (10) as claimed in claim 3, wherein the base (14) comprises a second bracket (24) extending from the peripheral wall, the second bracket supports a lock mechanism (30) to lock the cap (12) in the closed position.
8. The fuel tank cap assembly (10) as claimed in claim 1, wherein the arm (16) limits pivotal movement of the cap (12) by abutting the base (14) in the open position.