The present invention relates to fuel pump modules which are interfaced with fuel tanks for motor vehicles, and more particularly to a by-pass fuel system, wherein when waxed diesel fuel blocks the fuel pump fuel strainer, waxed fuel is able to by-pass the fuel pump fuel strainer via an auxiliary fuel port and by-pass valve.
Motor vehicle fuel tanks provide not only a reservoir for fuel but also must have accommodation for adding fuel, delivering fuel (i.e., to the engine) and monitoring the amount of the fuel therein. It has become a common practice to combine the fuel delivery and monitoring functions via a fuel pump module which is removably interfaced with an opening of the fuel tank outershell.
The fuel pump module 14 is part of a by-pass fuel system. With respect to by-pass fuel systems, there are feed and by-pass fuel lines which loop the fuel back to the fuel pump module or loop the fuel within the fuel pump module. The term “by-pass fuel system” refers to both “return fuel systems” and “mechanical returnless fuel systems”.
The by-pass fuel system continuously pumps fuel, and any amount not utilized by the engine is returned, via a return fuel line 34, as a by-pass strained fuel FB to the fuel pump module 20, wherein a pressure regulator (not shown) may be located between the fuel pump 24 and the diesel engine 40. The by-pass strained fuel FB is discharged by a jet pump 36 via a standpipe 38 into the module reservoir 22. In this regard, because the by-pass strained fuel FB mixes with the reservoir fuel FR already in the module reservoir, it becomes no longer separate as a uniquely identifiable entity and becomes merely a mixed aspect of the reservoir fuel FR component, wherein all of the reservoir fuel must be strained before entry to the fuel pump.
While this arrangement of the prior art works well, there could be a situation in which the diesel fuel waxes in the sense it “clouds”, becoming too viscous to pass through the fuel pump fuel strainer, whereupon fuel passage through the fuel pump fuel strainer could become strangled. Such a situation might occur, for example, if very cold conditions are present in which waxing of the diesel fuel and/or ice crystallization occurs causing fuel blockage at the fuel pump fuel strainer, whereupon the diesel engine may become starved of fuel.
Accordingly, it would be desirable for by-pass fuel systems if somehow when waxed fuel blocks the fuel pump fuel strainer, nevertheless waxed fuel will be delivered at the rate requested by the engine via the fuel pump.
The present invention is a by-pass fuel system configured so that in the event diesel fuel has waxed and/or ice crystals have formed such that the fuel is blocked at the fuel pump fuel strainer, the diesel fuel is selectively able to pass through an auxiliary fuel port to the fuel pump, thereby maintaining compliance with fuel demand of the diesel engine.
The fuel wax by-pass system according to the present invention features and an auxiliary fuel port, a normally closed by-pass valve (i.e., a pressure relief valve), and, optionally, an auxiliary coarse fuel strainer, wherein the fuel wax by-pass system is fluidically connected with the fuel pump. The normally closed by-pass valve prevents fuel from passing through the auxiliary fuel port to the fuel pump unless at least a predetermined fuel pressure differential exists between the (lower) fuel pressure internal to the fuel pump fuel strainer and the (higher) fuel pressure adjacently external to the fuel pump fuel strainer, wherein then the by-pass valve switches to an open state such that fuel is allowed to flow through the auxiliary fuel port to the fuel pump.
In operation, diesel fuel will normally flow freely through the fuel pump fuel strainer such that the fuel pressure differential as between the fuel pressure external and internal to the fuel pump fuel strainer is less than the predetermined fuel pressure differential in response to fuel pumping by the fuel pump, wherein the by-pass valve is in its normally closed state and no fuel passes through the auxiliary fuel port. In the event the fuel becomes blocked at the fuel pump fuel strainer, as for example in a situation in which the fuel has waxed and/or ice crystals have formed, as for example in a cold fuel tank environment, such that the fuel does not flow freely through the fuel pump fuel strainer in response to fuel pumping by the fuel pump, then the fuel pressure differential will increase. Should the fuel pressure differential reach (or exceed) the predetermined fuel pressure differential, the normally closed by-pass valve, which senses the fuel pressure differential, will thereupon assume an open state, whereupon the waxed fuel and/or crystals can now pass through the auxiliary fuel port and the auxiliary coarse fuel strainer, if present, to the fuel pump, thereby providing the fuel rate required by the engine. As long as the differential fuel pressure remains greater than the predetermined fuel pressure differential, the by-pass valve will remain open and allow passage of fuel through the auxiliary fuel port to the fuel pump. However, when the waxing and/or crystallization has lessened (i.e., dissolved) such that the fuel pressure differential has lowered so as to pass below the predetermined fuel pressure differential, then the by-pass valve will assume its normally closed state so as to prevent fuel from flowing through the auxiliary fuel port.
It is preferred for the auxiliary fuel port to be disposed at an elevated position in the module reservoir, being elevated with respect to the fuel pump fuel strainer, whereby contaminants will be generally disposed beneath, and away from, the auxiliary fuel port. It is further preferred for the return strained fuel to be flowingly discharged as a stream toward (i.e., onto) the fuel pump fuel strainer, whereby the return fuel warmed by heat of the diesel engine will tend to assist dissolving (i.e., melting) of any waxed fuel and/or ice crystals surrounding the fuel pump fuel strainer.
Accordingly, it is an object of the present invention to provide a by-pass fuel system configured so that in the event diesel fuel has waxed and/or ice crystals have formed such that the fuel is blocked from passing through the fuel pump fuel strainer, the diesel fuel will be selectively able to pass through an auxiliary fuel port so as to thereby maintain compliance with fuel demand from the diesel engine.
This and additional objects, features and advantages of the present invention will become clearer from the following specification of a preferred embodiment.
Referring now to the Drawing,
A module reservoir 102 is defined by a plastic module sidewall 102a. A fuel pump 104 draws reservoir fuel FR through a hollow fuel pump fuel strainer 106 in the module reservoir, and the strained fuel FS is then pumped by the fuel pump 104 to the diesel engine 108, wherein the strained pumped fuel FP is then delivered to the diesel engine via a feed fuel line 110 with an inline fuel filter 112.
The by-pass fuel system continuously pumps diesel fuel, and any amount not utilized by the engine is returned, via a return fuel line 114, as a by-pass strained fuel FB to the fuel pump module 100, wherein a pressure regulator (not shown) may be located between the fuel pump 104 and the diesel engine 108. The by-pass strained fuel FB is discharged as a fuel flow stream FO flowing directly onto the fuel pump fuel strainer 106 via a jet pump 116 disposed at the end of a standpipe 118, and thereupon mixes with, and becomes part of, the reservoir fuel FR. In this regard, because the output fuel flow stream FO has been heated by heat from the diesel engine 108, this heat is, in turn, imparted to the reservoir fuel surrounding the fuel pump fuel strainer 104, whereby any waxed fuel and/or ice crystals are dissolved.
So that the fuel pump module 100 is able to operate well at temperatures in which the fuel has waxed and/or ice crystals have formed causing blockage of passage of the reservoir fuel FR through the fuel pump fuel strainer 106 to the fuel pump 104, a fuel wax by-pass system 120, 120′, 102″ according to the present invention is provided.
Referring now to
The auxiliary coarse fuel strainer 122, which although optional, is preferred to be included (by way of comparison, the auxiliary coarse fuel strainer is not included at
The location of the auxiliary fuel port 128 (and preferably the location of the auxiliary coarse fuel strainer 122, if present) is preferably elevated in relation to the module reservoir 102. For non-limiting example, the auxiliary fuel port 128 may be disposed between about 20.0 mm and about 50.0 mm in height from the floor of the module reservoir 102. In this regard, because contaminants tend to form sediments at the bottom portion of the module reservoir 102, by placing the auxiliary fuel port 128 high in the module reservoir, yet below typical fuel level in the module reservoir so as to be disposed in the fuel, the likelihood of the sentimented particulates reaching the auxiliary fuel port is minimized.
In order to provide an elevated disposition of the auxiliary fuel port 128, as shown at
The normally closed by-pass valve 124 is, for example, a resiliently biased closed pressure relief valve, or other normally closed valve, in which the open and closed states are pressure determined, and wherein the by-pass valve is normally closed under normal operating fuel pressures. The by-pass valve 124 is disposed between the auxiliary fuel port 128 (and also the auxiliary coarse fuel strainer 122, if present) and the fuel pump 104, most preferably the hollow of the fuel pump fuel strainer 106, 106′, and senses the fuel pressure differential as between the fuel pressure P1 of the reservoir fuel FR at its external valve side 124a and the fuel pressure P2 of the strained fuel FS within the fuel pump fuel strainer at its inner valve side 124b, wherein if P1 minus P2 equals the differential pressure, ΔP.
The normally closed by-pass valve 124 prevents fuel from passing through the auxiliary fuel port 128 to the fuel pump 104 when in its closed state, but allows fuel to pass through the auxiliary fuel port to the fuel pump when in its open state. A predetermined fuel pressure differential ΔPP is determined, for example based upon empirical testing or other method, which is indicative of a fuel flow situation in which fuel is being blocked at the fuel pump fuel strainer 106, 106′ as for example due to waxing or icing. If the pressure differential ΔP sensed at the by-pass valve 124 between the (lower) fuel pressure P2 internal to the fuel pump fuel strainer and the (higher) fuel pressure P1 external to the fuel pump fuel strainer is such that ΔP<ΔPP, then the by-pass valve remains in its closed state; however, if ΔP>ΔPP, then the by-pass valve switches to its open state such that fuel is allowed to flow through the auxiliary fuel port to the fuel pump.
In operation, diesel fuel will normally flow freely through the fuel pump fuel strainer 106, 106′ such that the fuel pressure differential as between the fuel pressure external and internal to the fuel pump fuel strainer is less than the predetermined fuel pressure differential in response to fuel pumping by the fuel pump 104, wherein the by-pass valve 124 is in its normally closed state and no fuel passes through the auxiliary fuel port 128. In the event that the fuel has waxed and/or ice crystals have formed, as for example in a cold fuel tank environment, the fuel may be blocked at the fuel pump fuel strainer and not flow freely therethrough in response to fuel pumping by the fuel pump, whereupon the fuel pressure differential increases. Should the fuel pressure differential exceed the predetermined fuel pressure differential, the normally closed by-pass valve will switch to its open state, whereupon the waxed fuel and/or crystals can now pass through the auxiliary fuel port (and through the auxiliary coarse fuel strainer, if present) and into the fuel pump, thereby providing the fuel rate required by the engine. As long as the differential fuel pressure ΔP remains greater than the predetermined fuel pressure differential ΔPP, the by-pass valve will remain in its open state and allow passage of fuel through the auxiliary fuel port to the fuel pump. However, when the waxing and/or crystallization has lessened (i.e., the wax/ice has dissolved) such that the fuel pressure differential has lowered so as to pass below the predetermined fuel pressure differential (i.e., ΔP<ΔPP), then the by-pass valve will switch back to its normally closed state.
Thus, it is seen that the fuel wax by-pass system according to the present invention includes unique and advantageous features. The fuel pump fuel strainer, which for diesel fuel is generally a weave, will clog when the diesel fuel temperature drops below its “cloud” point. However, in such circumstance the by-pass valve will open and the waxed fuel can pass through the auxiliary fuel port to the fuel pump. The auxiliary fuel port is disposed relatively high in the module reservoir, spaced away from settled particulates. The mesh size of the openings of the auxiliary coarse fuel strainer (if provided) are larger than that of the fuel pump fuel strainer, but yet will strain large particulates from passing to the fuel pump. Further, the module reservoir jet pump discharge is directed directly onto the fuel pump fuel strainer, which will speed elimination of waxed fuel and/or ice crystals around the fuel pump fuel strainer by raising the fuel temperature, in that the discharge is in the form of warmed engine return fuel.
To those skilled in the art to which this invention appertains, the above described preferred embodiment may be subject to change or modification. Such change or modification can be carried out without departing from the scope of the invention, which is intended to be limited only by the scope of the appended claims.