FORM 2
THE PATENTS ACT 1970
(39 of 1970)
&
THE PATENTS RULES, 2003
COMPLETE SPECIFICATION (See Section 10; rule 13)
TITLE OF THE INVENTION In-tank Fuel Pump testing apparatus and method of testing thereof
APPLICANTS


TATA MOTORS LIMITED, an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India
INVENTORS
Mr. Swapnil R. Salunkhe, Mr. Dinkar A. Patil and Sachin V. Lafe
all Indian national of TATA MOTORS LIMITED an Indian company
having its registered office at Bombay House,
24 Homi Mody Street, Hutatma Chowk,
Mumbai 400 001 Maharashtra, India

PREAMBLE TO THE DESCRIPTION
The following specification particularly describes the invention and the manner
in which it is to be performed


FIELD OF INVENTION
This invention relates to apparatus used for testing automobile systems and more particularly it relates to apparatus and method of testing In-tank fuel pump.
BACKGROUND OF INVENTION
In-tank fuel pump durability test is conducted to know the deterioration of In-tank pump performance parameters.
The In-tank pump tests involves, the In-tank pump fitted inside the application vehicle fuel tank and fuel tank system related components. The durability test on In-tank pump is conducted for determining deterioration in In-tank pump performance parameters. In the present test method single pump is tested on stand alone test stand with constant & predetermined fuel level for predetermined test duration. During the test the pump is supplied with rated power supply and pump performance parameters like pump flow, Pressure and motor current are monitored. With this test method following are the shortfalls.
• Single pump tested at a given time.
• During the test the fuel level in test tank is maintained at constant level, however in actual usage the In-tank pump works with changing fuel levels as with the usage the fuel level decreases.
• No study of the effect of steel tank corrosion, coating dissolution on pump durability.
• Pump not exposed to in tank sealed environment of temperature, pressure humidity etc.
It is proposed to use two identical vehicle application tanks fitted with In-tank pump for conducting the durability test.

Two In-tank pumps are mounted in separate fuel tanks. The individual fuel tank is modified to provide two additional ports. The individual ports on each tank are connected to each other using rubber hoses. The purpose of this interconnection is to equalize level of fuel in tank during the test and ensure that In-tank pump do not run dry. The In-tank pumps are supplied with regulated power supply. The outlet connection of each In-tank fuel pump is connected to return line connection of other In-tank pump through an in line fuel filter. This ensures that each In-tank pump outlet flow is filtered and is then regulated through pressure regulator fitted on In-tank pump return connection. The vent connections on each tank are connected to evaporative carbon canister to ensure safe air breathing of fuel tanks throughout the test. One tank is filled with application fuel e.g. gasoline. The fuel filling neck on each tank is closed using sealing plugs. The individual In-tank pump is connected to a regulated power supply. The durability test is conducted by switching ON In-tank fuel pump in each tank alternatively during pre determined durations. The test cycles are controlled & counted by cycle counter fitted in a timer controller circuit.
OBJECTS OF INVENTION
> The main object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof by simulating In-tank pump usage with decreasing fuel level in fuel tank system.
> Yet another object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof which uses all the major fuel system
components.

> Yet another object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof which is simple in construction, cost effective and safe in operation.
> Yet another object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof which is used for durability test of In-tank pump regulator.
> Yet another object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof which is used for durability test of in line fuel filter.
> Yet another object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof which is used for durability test of different make of pumps under similar test conditions.
> Yet another object of this invention is to provide an In-tank pump testing apparatus and method of testing thereof which is used for ageing of fuel and vapor lines in actual test setup.
BRIEF DESCRIPTION OF THE INVENTION
In the proposed test method, In-tank pumps are mounted in separate fuel tanks. The individual fuel tank is modified to provide two additional ports. The individual ports on each tank are connected to each other using a rubber hose. The purpose of this interconnection is to equalize level of fuel in tank during the test and to ensure that

the In-tank pumps do not run dry. The In-tank pumps are supplied with regulated power supply. The outlet connection of each In-tank fuel pump is connected to return line connection of other In-tank pump through an in line fuel filter. This ensures the pump outlet flow is filtered and regulated through pressure regulator fitted on each pump return connection. The vent connections on each tank are connected to evaporative carbon canister to ensure safe air breathing throughout the test. One tank is filled with application fuel e.g. gasoline. The fuel filling neck on each tank is closed using sealing plugs. The individual In-tank pump is connected to a regulated power supply. The durability test is conducted by switching ON In-tank fuel pump in each tank alternatively during pre determined durations. The test cycles are controlled & counted by cycle counter fitted in a timer controller circuit.
BRIEF DESCRIPTION OF DRAWING
Figl. Shows In-tank fuel pump test apparatus fitted inside the fuel tanks in accordance with this invention
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting the same, Referring to fig. 1
In the proposed test setup, Two In-tank pumps (2) (5) are mounted in separate fuel tanks (1) (4). The fuel tanks are modified to have additional ports connected to each other (9, 11; 10,12). The purpose of this interconnection is to equalize level of fuel in

tank during the test and to ensure that the pumps (2 & 5) do not run dry. The port 9 and port 11 of first tank (1) connected to port 10 and 12 of second tank (4) respectively. The fuel tanks are filled with fuel e.g. petrol, diesel and/ or test fuel with pre determined quantity. The fuel tank filler necks are sealed with sealing arrangement (16) (17). The individual in-tank pump outlet fuel connections (20) (21) are connected to return line port (22) (23) of other in-tank pump through in line filter (3) (6). This ensures the pump outlet flow is filtered and regulated through pressure regulators (7) (8) fitted on each pump return connections. The vent connections (13) (19) on individual tanks are connected to evaporative carbon canister (14). This ensures safe air breathing throughout the test. The in-tank fuel pumps are connected to test controller (15) & the pumps are supplied with regulated power supply.
The in-tank pumps are switched ON and OFF at pre determined time based on the pump delivery specifications. The test cycles are counted by cycle counter fitted in test controller unit (15). The steps of the test methods are as follows
a) Fill the tank 1 with fuel up to 70-85% of the tank capacity and maintained the second tank empty;
b) Switch ON the In-tank pump located in the first tank for predetermined period;
c) During the above period fuel pumped from first to second tank if the second tank gets filled then the level equalizer start functioning through the ports (9 & 10);
d) Switch OFF the intake pump located in first tank after said predetermined period and Switch ON the intake pump located in second tank using a controller with timer input;

e) During the this period the first tank gets filled and level equalizer start functioning through the ports (11 & 12);
f) Switch OFF the intake pump located in second tank after same predetermined period and switch ON intake pump located in first tank ;
g) The above switch ON/OFF controlled by a controller with timer input;
h) Repeat the procedures above for a specific time and record the intake pumps ON and OFF cycles.
The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purpose of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.

WE CLAIM
1. An in-tank fuel pump test apparatus comprising:
two fuel tank with in-tank fuel pump;
pair of connection ports provided on each fuel tank, said ports on one fuel tank being adapted to be connected to the ports on the other fuel tank to equalize level of fuel in tank;
outlet fuel connections of each of said fuel pump are connected to return line port of the other pump through filter means; and
a control means connected to said fuel pumps to regulate power supply to the in-tank fuel pumps.
2. The apparatus as claimed in claim 1, wherein sealing plugs are provided at fuel tank filler necks to seal said fuel tank.
3. The apparatus as claimed in claim 1, wherein each of said fuel tank comprises vent connections that are connected to an evaporative carbon canister for safe air breathing throughout the test.
4. The apparatus as claimed in claim 1, wherein it comprises power supply means to provide regulated power supply to said fuel pumps.
5. A method to determine durability of in-tank fuel pump using an apparatus as claimed in any one of the preceding claims comprising the steps of:
filling first of said two fuel tank with a pre-determined amount of fuel; switching ON the power supply to said first fuel pump for a pre-determined period of time to pump the fuel from first tank onto the second tank;

maintaining a predefined level of fuel in said first and second fuel tanks using the level equalizer ports;
switching OFF the power supply to said first pump located in first tank after said predetermined period;
switching ON the power supply to said second fuel pump located in said second tank using a controller with timer input;
maintaining a predefined level of fuel in said first and second fuel tanks using the level equalizer ports;
switching OFF power supply to the second pump located in second tank after same predetermined period;
switching ON power supply to said first pump located in first tank;
repeating the above procedure for a specific time; and
recording the ON and OFF cycles of said first and second pumps.
6. An in-tank fuel pump test apparatus as hereinabove described with reference to the accompanying drawings.
7. A method to determine durability of in-tank fuel pump as hereinabove described with reference to the accompanying drawings.
Dated this 29th day of December 2008