FUEL LEVEL SENSOR FOR MARINE FUEL VAPOR SEPARATOR

EXTERNAL TO UNIT

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to Provisional Patent Application No. 61/434,461 filed January 20, 201 1, the entire disclosure of which is hereby incorporated by reference and relied upon.

BACKGROUND OF THE INVENTION

1. Field of the Invention

[0002] The present invention is related to vapor separators, and more particularly to vapor separators for fuel systems of marine engines.

2. Related Art

[0003] Fuel vapor is a long recognized issue in the marine fuel industry. Small outboard marine engines, including transom mounted and stern drive units frequently utilize an integrated fuel system which draws liquid fuel under suction from a can or tank located in the boat. The fuel is drawn under suction because boat safety regulations require that fuel routed between the tank and engine be sucked under a vacuum to prevent fuel from spilling into the boat should the fuel line rupture. However, the fact that fuel is withdrawn from the tank at a negative pressure can be problematic because, at such low pressures, the fuel can readily evaporate. This, combined with the vapor- producing effects of high temperatures and jarring conditions, could lead to vapor lock and diminished pumping efficiencies if not addressed.

[0004] The excessive vapor issue is typically addressed by routing the fuel through a fuel vapor separator unit and then delivering it at a high pressure to the fuel injection system of the engine. In addition to the naturally arising vapors from the vacuum drawing steps, unused, hot fuel from the fuel rail is returned to the vapor separator where fuel vapors are condensed back to liquid before the fuel is reintroduced to the high Attorney Docket #710240-5916 pressure pump and fuel rail. Uncondensed fuel vapors can be vented to atmosphere or pulled into the engine intake system through a vacuum line connection.

[0005] Figures 1 and 2 generally depict an outboard marine engine 12 affixed to the transom 14 of a boat, as described more fully in Applicant's US Patent No. 7,503,314, the entire disclosure of which is hereby incorporated by reference. Outboard marine engines 12 of this type are often mounted to a bracket 16 so that the engine 12 can be quickly removed from the boat for transportation and/or maintenance. The bracket 16 in this example allows the motor head to be rotated about axis A launching, shallow conditions maneuvering, and trim control.

[0006] An engine of the type shown in Figure 1 , as well as other marine engine types, commonly run on a liquid fuel like gasoline or ethanol. Liquid fuel is drawn from a fuel tank 20 by an engine-mounted marine fuel system, such as the system generally shown at 22 in Figure 2. Except for the fuel tank 20 and a supply line 24, the remainder of the fuel system 22 is typically (but not necessarily) integrated into the engine 12.

[0007] In operation, a low pressure fuel supply pump 26 sucks fuel from the tank 20 through the supply line 24. The fuel is delivered to a vapor separator, generally indicated at 28. The vapor separator 28 collects and discharges vapors given off from the incoming low pressure fuel and also from the hot, agitated fuel returning from the engine 12. A high pressure pump 30 then pumps the fuel under pressure into the fuel injector system 32 to be consumed by the engine. Unused fuel is returned to the vapor separator 28 via return line 34. A vent valve device, generally indicated at 36, may be provided for connection to the engine intake vacuum system. The vacuum system creates a negative pressure in the vent line 40 so that fuel vapors can be cycled through the engine 12.

[0008] The low pressure fuel supply pump 26, also known as a lift pump, may be of the pulsed diaphragm type or any other suitable type. Diaphragm type fuel pumps are sometimes preferred in these applications because they are less susceptible to pumping problems when the fuel is hot and there is a high vapor concentration. Typically, these pulsed diaphragm pumps are operated by air pressure fluctuations generated in the crank case portion of the engine 12. One exemplary pulse pump is shown in Applicant's own US Patent No. 6,158,972, which is incorporated herein by reference in its entirety.

[0009] Figure 3 shows a simplified, cross-sectional view of one known type of fuel vapor separator assembly 28'. The lift pump 26' is of the diaphragm type but not Attorney Docket #710240-5916 energized by engine pulses. Rather, an electro-mechanical device is used to reciprocate a diaphragm (not shown) within the lift pump 26' to generate the vacuum. The electromechanical device may be a linear motor (e.g., a solenoid), a rotating shaft motor, or any other type of electro-mechanical machine. Fuel is drawn, under vacuum, from a tank (not shown) through the supply line 24' and discharged into the interior of the fuel vapor separator assembly 28' via inlet 50'. Hot fuel returning from the fuel injectors via return line 34' also enters the interior of the vapor separator assembly 28' and intermingles with fuel delivered from the lift pump 26'. A cooling tube 52' is positioned inside the vapor separator 28' for the purpose of exchanging heat and reducing the temperature of fuel inside the vapor separator 28'. A continuous supply of water is fed through the cooling tube 52' from an inlet 54' to an outlet 56'. A vapor vent 35' allows fuel vapors to be drawn out of the fuel vapor separator 28'. A high pressure pump 30' draws fuel from a fuel intake 42' and discharges the fuel through an outlet 44' to the fuel injection system of the engine.

[0010] Considering the lift pump 26' in greater detail, Figure 3 shows an power source 60' for powering the electro-mechanical device inside the lift pump 26'. A manual prime lever 62' may be included for the purpose of manually priming the lift pump 26' in appropriate circumstances.

[0011] As will be understood by those of skill in the art, many known vapor separators, such as those described above in connection with Figures 2 and 3, use a float/needle assembly 36, 36' for fuel vapor out control and/or fuel inlet control. However, such float/needle assemblies 36, 36' are susceptible to wear and leakage. Alternative concepts have been developed using electronic sensors (not shown) disposed inside of the vapor separator unit which require routing wires through the separator housing using some form of pass-through sealed connector. Such pass-through sealed connectors often leak and can be associated with common failure modes.

SUMMARY OF THE INVENTION

[0012] At least one aspect of the subject invention provides for a marine fuel vapor separator with an externally mounted sensor. The vapor separator includes a housing having an open interior and a float disposed in the housing. The float is moveable in a Attorney Docket #710240-5916 vertical direction in response to changing fluid levels in the open interior between a pair of pre-established constraints. At least one magnet is disposed on the float, and a sensor assembly which is responsive to movement of the magnet is disposed externally of the housing. When the fluid level of the tank lowers, the sensor assembly detects the lowering of the float and transmits a signal to a controller, which takes remedial action by activating a fuel lift pump to pump additional fuel into the vapor fuel separator and/or opening a vapor vent valve to discharge vapors out of the fuel vapor separator.

[0013] The externally mounted sensor assembly with the separate vapor vent valve is advantageous over float/needle assemblies because it is less susceptible to wear and leakage. Additionally, because the sensor is mounted externally of the housing, a pass- through connector for running wires into the housing is not required. Thus, the fuel vapor separator is more reliable and less susceptible to wear and leakage than other known fuel vapor separators.

[0014] The marine fuel vapor separator could be used with any type of boat engine, e.g. an outboard motor, an inboard/outboard motor or an inboard motor. It could also be mounted internally to or externally of to the engine. The sensor assembly could be any type of sensor assembly which is responsive to magnetic fields including, for example, a Hall effect sensor or a reed-type sensor. A Hall Effect sensor might be preferred for reliability purposes because it has no moving parts.

[0015] According to another aspect of the invention, the sensor assembly includes a pair of sensor elements spaced vertically from one another. One of the sensor elements generates an electric signal when the float and magnet are in an uppermost position, and the other sensor element generates a different electrical signal when the float and magnet are in a lowermost position.

[0016] According to yet another aspect of the invention, a pair of magnets spaced vertically from one another are disposed on the float, and the sensor assembly only includes a single sensor element. The magnets have either different strengths from one another or different polarities. When the float is in an uppermost position, one of the magnets is in proximity with the sensor element, and the sensor element generates a signal. When the float is in the lowermost position, the other magnet is in proximity with the sensor element, and the sensor element generates a different signal. Attorney Docket #710240-5916

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and other features and advantages of the present invention will be readily appreciated, as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0018] Figure 1 is a side and elevation view of a known outboard marine engine;

[0019] Figure 2 is a schematic view of a known engine mounted marine fuel system;

[0020] Figure 3 is a cross-sectional view of a known vapor fuel separator;

[0021] Figure 4A is a cross-sectional and fragmentary view of a vapor separator constructed according to one aspect of the invention with a float being in an uppermost position;

[0022] Figure 4B is a cross-sectional and fragmentary view of the vapor separator of Figure 4A and with the float being in a lowermost position;

[0023] Figure 5 is a schematic view of a marine fuel delivery system constructed according to an aspect of the subject invention;

[0024] Figure 6A is a cross-sectional and fragmentary view of a vapor separator constructed according to another aspect of the invention with a float being in an uppermost position;

[0025] Figure 6B is a cross-sectional and fragmentary view of the vapor separator of Figure 6A and with the float being in a lowermost position;

[0026] Figure 7A is a cross-sectional and fragmentary view of a vapor separator constructed according to yet another aspect of the subject invention and with the float being in an uppermost position;

[0027] Figure 7B is a cross-sectional and fragmentary view of the vapor separator of Figure 7A and with the float being in a lowermost position; and

[0028] Figure 8 is a flow chart of an exemplary method of operating a marine fuel delivery system. Attorney Docket #710240-5916

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0029] Referring to Figures 4A and 4B, a fuel vapor separator assembly constructed according to one aspect of the present invention is shown generally at 128. For convenience, features like or corresponding to in those described above are indicated with previously established reference numerals together with factors offset by 100. In this design, the float assembly 148 includes a puck-like float body 180 slideably carried on a short shaft 182 extending downwardly from a cap 184 on a housing 146. A retainer clip 186 is attached to the distal end of the shaft 182 as a keeper to trap the float 180 on the shaft 182 and inside the vapor separator 128. The float body 180 may be circular or any other suitable shape. The float body 180 is less dense than the preferred fuel for the engine, and thus, the float body 180 is responsive to the level of fuel in the vapor separator unit 128 and is moveable along the shaft 182 between an upper constraint established by the cap 184 and a lower constraint established by the retainer clip 186. The vapor separator 128 also includes a vent pipe 138 extending outwardly from the cap 184 for venting fuel vapors out of the open interior, as will be discussed in further detail below. Further, the fuel vapor separator 128 includes a cooling tube 152 for exchanging heat between water and the fuel in the fuel vapor separator 128. The fuel vapor separator 128 could be used with any desirable type of marine engine including, for example, outboard engines, inboard/outboard engines or inboard engines.

[0030] At least a portion of the outer edge, or the perimeter, of the float body 180 carries at least one magnet 188. Directly opposite the magnet 188 and disposed externally of the housing 146 is a sensor assembly 190 which is responsive to magnetic fields. The externally mounted sensor assembly 190 is preferably of the Hall Effect type, i.e. the sensor assembly 190 produces a voltage (the Hall voltage) in response to a magnetic field. Hall Effect sensors generally have no moving parts, and thus, are known to offer enhanced reliability in extreme environments. They also have a long life expectancy as compared to the traditional float/needle assemblies 36, 36' described above and other types of electromechanical switches. The sensor assembly 190 can be mounted to the exterior of the housing 146 using any suitable technique, such as Attorney Docket #710240-5916 welding, brazing, bonding or mechanical fasteners. Preferably, the sensor assembly 190 is encapsulated in an appropriate protective material which does not have to be of a material resistant to fuel because the sensor assembly 190 is not disposed in the interior of the housing 146.

[0031] The sensor assembly 190 of this embodiment is a dual detection type device including first 192 and second 194 sensing elements. Each sensing element 192, 194 is responsive to the magnet 188 moving into proximity therewith or to the magnet 188 moving away therefrom. In Figure 4 A, the fuel level in the vapor separator 128 is very high, and thus, the float 180 is shown in an upper-most position such that the magnet 188 is in proximity with the first sensing element 192. The sensor assembly 190 then generates an electrical signal of the type well-known to those of skill in the electronic sensor arts. The electrical signal thus generated may be transmitted via an electrical cable 196 or wirelessly to a controller 198 (shown in Figure 6), as will be discussed in further detail below. In Figure 4B, the fuel level in the vapor separator 128 is low, and thus, the float 180 is in a lower-most position with the second sensing element 194 being in proximity with the magnet 188. The sensor assembly 190 then generates a different electrical signal which is also transmitted via an electrical cable 196 (or wirelessly) to the controller 198. As will be discussed in further detail below, when the fuel level in the vapor separator 128 is low, then undesirable fuel vapors are likely present in the vapor separator 128, which could cause vapor lock if not vented.

[0032] A schematic view of the marine fuel delivery system according to one aspect of the subject invention is shown in Figure 4. In operation, a lift pump 126 sucks fuel from the fuel tank 120 through the supply line 124. The fuel is delivered to the vapor separator 128, which collects and discharges vapors given off from the incoming low pressure fuel and also from the hot agitated fuel returning from the engine (not shown). A high pressure pump 130 then pumps the fuel under pressure into the fuel injector system 132 (or carburetor) to be consumed by the engine. Unused fuel is returned to the vapor separator 128 via a return line 134. A vent valve device 136 is attached to the vent pipe 138 for selectively allowing vapors to flow into the engine intake manifold via vent line 140 so that the vapors are cycled through the engine and burned. Alternately, the vapors could be discharged into the atmosphere. The fuel delivery system may also include at least one check valve 148 for preventing fuel from flowing back into the fuel Attorney Docket #710240-5916 tank 120 from the supply line 124 or from flowing to the fuel injectors 132 through the return line 134.

[0033] Referring back to Figures 4A and 4B, as discussed above, the first sensing element 192 is associated with a high fuel condition and the second sensing element 194 is associated with a low fuel condition. When the float 180 drops enough for the second sensor element 194 to detect the presence of the magnet 188, a signal is provided to a controller 198. The controller 198, in turn, takes remedial action by turning on the fuel lift pump 126 to inject more fuel into the vapor separator 128 and/or opening a vapor vent valve 136 to vent the fuel vapors out of the vapor separator 128. When the float 180 rises high enough for the first sensor element 192 to detect the presence of the magnet 188, a different signal is provided by the sensor assembly 190 to the controller 198, which takes remedial action by turning off the fuel lift pump 126 and/or by closing the vapor vent valve 136.

[0034] Those of skill in the art will appreciate alternative mounting arrangements for the float 180, such as a pivoting mount rather than the sliding arrangement shown. Other designs could also be implemented without departing from this concept of an externally mounted Hall Effect fuel level sensor 190 for a marine fuel vapor separator unit 128, which eliminates the need for pass-through connectors and enables a simplified design of the vapor separator unit 128 that is less susceptible to premature wear.

[0035] Figures 6A and 6B are similar to the Figures 4A and 4B, but illustrate a vapor separator 228 constructed according to an alternate aspect of the invention wherein like or corresponding parts use the same reference numbers but offset by 100. In this embodiment, the sensor assembly 290 includes only a single, reed-type sensor element 292 as opposed to the two sensor elements 192, 194 discussed above. As will be appreciated by those having skill in the art of electronics, a reed-type switch is an electrical switch which is either opens or closes in the presence of a magnetic field and returns to a rest state (either open or closed) when separated from the magnetic field. In this embodiment, the magnet 288 carried in the float 280 acts on the reed switch element 292 when the float 280 and the magnet 288 are in the lower-most position shown in Figure 6B. The sensor assembly 290, in turn, generates an electrical signal which is transmitted via the electrical cable 296 (or wirelessly) to a controller. Upon receiving the electrical signal, the controller takes remedial action, which might be turning the lift Attorney Docket #710240-5916 pump on and/or opening the vapor vent valve. It should be appreciated that the sensor assembly 290 could alternately be positioned to generate the electrical signal when the float 280 is in the upper-most condition. Even further, the reed-type switch assembly could be re-configured to operate in a dual-signal manner similar to the sensor assembly 190 shown in Figures 4A and 4B and discussed above.

[0036] Figures 7A and 7B are similar to the Figures 4A and 4B, but illustrate a vapor separator 328 constructed according to yet another aspect of the invention wherein like or corresponding parts use the same reference numbers but offset by 200. In this embodiment, the sensor assembly 390 includes only a single sensor element 392, and the float 380 carries two magnets 388-A and 388-B which are vertically spaced from one another and have either two different strengths or two different polarities. In this embodiment, magnet 388-A acts on the sensor element 392 when the float 380 is in lower-most condition shown in Figure 7B. The sensor assembly 390, in turn, generates an electrical signal which is transmitted via the electrical cable 396 (or wirelessly) to a controller. Upon receiving the electrical signal, the controller takes remedial action, which might be turning the fuel lift pump on to pump more fuel into the fuel vapor separator 328 and/or opening the vapor vent valve to discharge vapor from the fuel vapor separator 328. Then, when the float 380 is raised to the position shown in Figure 7A, magnet 388-B, which has a different strength or a different polarity than magnet 388-A, acts on the sensor element 392. The sensor assembly 390, in turn, generates a different electrical signal which is transmitted via the electrical cable 396 (or wirelessly) to the controller. Upon receiving this electrical signal, the controller takes remedial action, which might be turning the lift pump off and/or closing the vent valve. It should be appreciated that this embodiment of the vapor separator 328 could be reconfigured to accommodate a reed-type switch element, like that shown in Figures 6A and 6B.

[0037] Referring now to the flow chart of Figure 8, the vapor separator 128 of Figure 4 and the marine fuel delivery system of Figure 5, another aspect of the present invention is a method of operating a marine fuel delivery system. The method starts with the step 400 of providing a fuel vapor separator 128 having an open interior with a float 180 disposed therein, wherein the float 180 is moveable in the open interior within pre- established constraints in response to changing fluid levels and wherein at least one magnet 188 is disposed on the float 180. The method continues with the step 402 of Attorney Docket #710240-5916 providing a sensor assembly 190 responsive to the magnet 188 and disposed externally of the fuel vapor separator 128. As discussed above, the sensor assembly 190 could be, for example, a Hall Effect type sensor, a reed-type sensor or any other type of sensor responsive to magnetic fields.

[0038] The method then continues with the step 404 of activating the sensor assembly 190 in response to the float 180 being in either the upper or the lower of the vertically spaced pre-established constraints. The method may also include the step 406 of pumping fuel into the open interior of the fuel vapor separator 128 with a fuel lift pump 126 and/or venting fuel vapors out of the open interior with a vapor vent valve 136 in response to the sensor assembly 190 detecting that the float 180 is in the lower of the pre-established constraints. The method may additionally include the step 408 of deactivating the fuel lift pump 126 and/or closing the vapor vent valve 136 in response to the sensor assembly 190 detecting that the float 180 is in the upper of the pre-established constraints.

[0039] The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.