Research on low temperature fuel heating system for heavy vehicles

In cold ambient conditions, starting a diesel engine can be challenging. This issue is often caused by problems in the fuel supply system. Two primary factors are at play: first, when temperatures drop below 0°C, moisture in the diesel fuel can freeze, forming small ice particles that clog the fuel filter and fuel lines. Second, low temperatures increase the viscosity of diesel, causing wax to precipitate from the fuel, which restricts fuel flow and makes it harder for the engine to start. A common solution is to use diesel with a suitable cold-weather rating or add antifreeze to improve fuel flow. However, high-grade diesel is more expensive and less efficient, leading to higher operating costs. Another approach involves heating the fuel tank or using hot water to warm the fuel lines, but this method is inconvenient and poses safety risks. To address these issues, an **automatic temperature-controlled low-pressure fuel heating system** has been developed. This system allows the use of lower-grade diesel, such as 0# diesel, even in temperatures as low as -10°C, ensuring smooth engine startup. The system includes components like an electric heating oil quantity sensor, heated fuel pipes, an integrated fuel pump filter, and a fine filter heating jacket. The electric heating oil quantity sensor not only monitors fuel levels but also acts as a fuel outlet pipe, allowing the heater to be installed directly in the discharge line. This helps dissolve diesel wax and improve fuel flow. The heater uses PTC material, which provides automatic temperature control, no open flame, and corrosion resistance. Inside the fuel pipe, a nickel-chromium alloy heating wire is embedded. It offers strong oxidation resistance and consistent heat generation, maintaining durability under repeated temperature changes. The heating power per meter is set to about 20W, adjusted based on the length of the fuel pipe to ensure uniform heating. The integrated fuel pump filter combines oil-water separation, filtration, and heating functions. It features a microcomputer unit and temperature sensor that activate the heating system when the fuel temperature drops below 2°C and deactivate it once the temperature rises above 20°C. The system automatically stops heating after 15 minutes of continuous operation for safety. The oil-water separator meets National III engine standards, with a 30μm filtration precision and 99% water separation efficiency. To reduce air bubbles in the fuel lines during restarts, an electromagnetic pump is included. It allows quick and easy air evacuation without manual effort, reducing pressure drop and improving engine start performance. Additionally, a heating jacket is wrapped around the fine filter to prevent wax buildup, enhancing overall system efficiency. The heating power is set to 60W, ensuring optimal performance without damaging the original fuel system. From an economic perspective, using 0# diesel instead of -10# diesel saves approximately 0.37 yuan per liter. With improved combustion efficiency, fuel consumption decreases by 1–3%. For a typical truck consuming 40 liters per 100 km, this could save up to 150 yuan per day. In conclusion, the automatic temperature-controlled low-pressure fuel heating system significantly improves the performance of heavy vehicles in cold environments. It enables the use of lower-cost diesel, enhances fuel efficiency, reduces carbon deposits, and delivers better economic returns. This technology represents a major advancement in the field of heavy-duty vehicle engineering.

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