Rajan Wilcox
Fuel tanks are containers for flammable fluids, such as gasoline or diesel fuel. They are part of an engine system that stores and propels fuel into the engine. Fuel tanks come in a variety of sizes and complexities, from small plastic tanks in lighters to multi-chambered cryogenic tanks in spacecraft. Fuel tanks are designed to store fuel, fill fuel securely, and determine the level of fuel in the tank. Fuel systems have become more complex over time, with advancements in ignition, timing, and fuel systems. Today, fuel systems can be complicated, with multiple pumps and injectors, and understanding their full function is important for proper maintenance.
| Characteristics | Values |
|---|---|
| Purpose | To safely store flammable fluids, often gasoline or diesel fuel |
| Function | To store and propel (fuel pump) or release (pressurized gas) fuel into an engine |
| Design | Fuel tanks range in size and complexity from small plastic tanks to multi-chambered cryogenic tanks |
| Filling | Fuel must be filled securely, without sparks, and with a method for determining the level of fuel in the tank |
| Safety | Intact fuel tanks are generally safe due to the fuel vapour/air mixture being above flammability limits |
| Protection | Military vehicles use systems like BattleJacket and rubber bladders to protect fuel tanks from enemy fire |
| Placement | Fuel tanks in cars are typically mounted laterally, while aircraft use "wet wings" or bladder tanks |
| Fuel Supply | Fuel pumps provide a constant supply of fuel to the engine, preventing fuel starvation |
| Fuel Circulation | There is a constant circulation of fuel from the tank through the system and back while the vehicle is running |
| Fuel Injection | Newer gasoline engines use direct injection, with a lift pump and pressure pump, while older engines used carburetors |
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Fuel tank design and safety
Safe Storage:
Fuel tanks must be designed to securely contain flammable fluids, preventing leakage and limiting evaporative emissions. The material used for construction is crucial, as some materials like plastic (HDPE) can become saturated with fuel over time, leading to environmental stress cracking and potentially catastrophic failure due to fuel flammability. Metal is a common material for fuel tanks, offering durability and resistance to fuel permeation.
Filling and Fuel Level Determination:
The process of filling a fuel tank must be safe and spark-free to prevent ignition. Additionally, fuel tanks should have a reliable method for determining the level of fuel, allowing users to gauge the remaining quantity accurately.
Fuel Propulsion:
Fuel tanks work in conjunction with fuel pumps to propel or release fuel into the engine. The design of the fuel tank should ensure smooth fuel flow to the pump, even when the vehicle is on inclines or declines. This can be achieved through features such as rounded bottoms, multiple intake points, and lift pumps that maintain a constant fuel level and prevent fuel starvation.
Safety Features:
To enhance safety, fuel tanks may incorporate baffles, solid plates that slow down fuel movement and reduce sloshing. Aircraft fuel tanks may also maintain a head of air pressure at the top, using NACA ducts to allow outside air to push down on the fuel. In military vehicles, additional protection is employed, such as BattleJacket and rubber bladders, to safeguard fuel tanks from enemy fire and explosions. Stationary fuel tanks can be protected by burying them, shielding them from temperature extremes and vehicle crashes.
Fuel System Maintenance:
Proper maintenance of the fuel system is essential for safety. Regular inspections, repairs, and replacements are necessary to ensure the fuel tank and associated components, such as fuel pumps and filters, are functioning correctly. This helps prevent issues like fuel starvation and maintains the overall reliability of the system.
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Fuel surge tanks
The design of fuel surge tanks varies, with some being installed internally and others externally to the fuel tank or fuel cell. They work in conjunction with common fuel pumps available on the market, such as Bosch 040, Walbro GSS341 & GST450, and Deatschwerks DW200, DW301, and DW400. Additionally, they can be used with externally mounted fuel pumps, such as the Bosch 044.
Overall, fuel surge tanks play a critical role in ensuring a stable fuel supply to high-performance engines, reducing the risk of engine damage due to fuel starvation and maximizing the utilization of engine power.
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Fuel pumps
The design of fuel pumps can vary, with electric and mechanical systems available. Electric pumps utilise a solenoid (an electromagnetic switch) to activate a diaphragm mechanism, creating suction and drawing fuel into the chamber. Mechanical pumps, on the other hand, may use a revolving cam and lever system to create suction and draw fuel through a one-way valve. Both types of pumps are designed to supply fuel only when the carburettor requires it, ensuring efficient fuel usage.
In modern vehicles, direct injection technology often employs two fuel pumps: a ""lift" or "transfer" pump within the fuel tank and a pressure pump mounted on the frame or subframe. The lift pump moves fuel out of the tank, while the pressure pump delivers it to the injectors at high pressure. This dual-pump system is common in both gasoline and diesel engines, providing the necessary volume and pressure of fuel for optimal engine performance.
Furthermore, fuel surge tanks or swirl pots serve as buffers, providing an additional layer of protection for the engine. These tanks ensure a constant fuel supply, reducing the risk of fuel starvation and potential engine damage. They are particularly useful in high-performance racing scenarios where fuel demand is high and fuel tank sloshing may occur.
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Fuel injectors
There are two main types of control for multi-port systems: simultaneous and sequential. In a simultaneous system, all the fuel injectors open at the same time. In a sequential system, each injector opens just before the intake valve for its cylinder, allowing the system to respond more quickly to sudden changes.
The pressure of the fuel in the injectors is regulated to the proper volume and pressure. This is usually between 50-90PSI for multi-port electronic fuel injection systems, though older carbureted engines operate at a lower pressure of 3-5PSI.
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Fuel storage
Tank Design and Materials: Fuel tanks can be made from various materials, including metal and plastic. Metal tanks, often constructed from high-density polyethylene (HDPE), are commonly used in aircraft, automobiles, and motorcycles. Plastic tanks are also viable for short-term fuel storage, but they may become saturated over time as fuels permeate the plastic, leading to environmental stress cracking and potential failure.
Safe Fuel Storage: Fuel tanks play a vital role in safely containing flammable fluids. In most cases, intact fuel tanks are very safe due to the fuel vapour-air mixture being above the flammability limit, preventing ignition. Additionally, bunded oil tanks are used for securely storing domestic heating oil and hazardous materials, reducing the risk of leakage and spills.
Fuel Tank Placement: The placement of fuel tanks varies depending on the vehicle or aircraft. In cars, fuel tanks are typically mounted laterally, reducing the impact of driving on inclines or declines. Aircraft, on the other hand, may use "wet wings," where fuel is stored in the wings, belly, or tail of the plane. Some smaller aircraft use rigid removable metal tanks, while bladder tanks made of reinforced rubber are also used in aviation.
Fuel Intake and Pump Systems: Fuel tanks are designed to maintain a consistent fuel supply to the engine. In cars, the fuel pump and filter are usually located in a low spot in the tank, ensuring fuel can be drawn even on inclines. Racing cars and off-road vehicles may have multiple intake points and lift pumps to manage fuel sloshing during high-performance driving. Aircraft may also use NACA ducts to allow outside air in, helping to push down the fuel and maintain stability.
Fuel Surge Tanks: These are auxiliary tanks that work as a buffer to protect the engine and minimize the risk of fuel loss. They ensure a constant level of fuel, reducing the chance of engine damage during high-power outputs or RPMs. Fuel surge tanks are particularly useful in high-performance race cars to maintain a steady fuel supply to high-pressure fuel pumps.
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Frequently asked questions
A fuel tank is a container for flammable fluids, such as gasoline or diesel fuel. It is part of an engine system in which the fuel is stored and propelled (fuel pump) or released (pressurized gas) into an engine. Fuel tanks range in size from small plastic tanks in lighters to the multi-chambered cryogenic Space Shuttle external tank.
Fuel tanks store and supply fuel to the engine cylinders. The fuel is mixed with air and becomes vapourised, then it moves to the engine cylinders to be burned to produce energy. While a vehicle is running, there is a constant circulation of fuel from the fuel tank through the system and back. Fuel is stored in the fuel tank where the fuel pump draws it and sends it through the fuel lines through a fuel filter to the fuel injectors.
Fuel tanks in cars are typically mounted laterally, meaning a car driving directly up or down a hill will affect the fuel tank far less than a car sitting sideways on a hill. A rounded bottom on a car's fuel tank helps to keep fuel at the bottom of the tank so the pump can continue to pump it toward the engine. Performance racing and off-roading tanks will have multiple intakes in each corner or possible "low" spot of the tank and a low-pressure system to always be able to draw fuel from at least one of the intakes.
