Optimizing the fuel system design can significantly reduce the risk of fuel hunger when going uphill. Research shows that when the slope exceeds 20%, the failure rate of fuel supply in traditional fuel tanks can be as high as 37%. The solution of installing a Surge Tank increases the fuel retention by 500ml, ensuring continuous fuel supply for 20 seconds at a 45-degree elevation Angle. In the 2023 Pikes Peak International Mountain Climbing Race, 85% of the finishing vehicles adopted a dual-pump redundancy system, with the main pump flowing at 255L/h and the auxiliary pump at 120L/h, reducing the probability of fuel supply interruption from 12% to 0.3% and keeping the engine power output fluctuation within ±2%.
The installation Angle of the fuel pump directly affects the fuel supply efficiency. When the vehicle’s tilt Angle reaches 30 degrees, the exposure probability of the suction port of the standard installed oil pump is 40%, while the use of a 15-degree pitch adjustment bracket can increase the oil level coverage to 98%. Real vehicle test data shows that on a 7-kilometer continuous uphill section, the optimized bracket has increased the fuel pressure stability to ±1.5PSI (originally ±6PSI), and the flow rate fluctuation has been compressed from 15% to 3%. The technical report of Subaru Rally Team indicates that this solution has increased the full throttle maintenance rate of the racing car by 22% and the average speed by 9km/h.
Optimization of the oil circuit diameter and layout can reduce flow resistance by 62%. The inner diameter of the oil supply pipe was increased from 6mm to 8mm. At a working pressure of 75PSI, the flow rate was reduced to 3.5m/s (originally 7.2m/s), and the friction loss was reduced by 19%. The case study of the Porsche Cayenne Turbo model shows that when equipped with the upgraded 10mm inner diameter hard pipe of the new Fuel Pump, the fuel flow rate remains constant at 200L/h during the uphill condition at an altitude of 2000 meters. The air-fuel ratio deviation of the oxygen sensor is only ±0.3 (the standard allows ±1.0), and the incidence of heat exhaustion is reduced by 45%.
The intelligent control system eliminates 72% of fuel supply risks through real-time data. The fuel pump adjustment module based on CAN bus can respond to slope changes within 0.1 seconds. When the tilt sensor detects an elevation Angle greater than 15 degrees, the pump voltage rises from 12V to 14.5V, and the flow rate instantly increases by 35%. The actual test of the BMW GTS series has proved that the system maintains a constant pressure fuel supply of 65PSI under the hairpin bend conditions in the Alps. The diameter of the fuel atomization particles is optimized to 15μm (20μm under standard conditions), the combustion efficiency is increased by 2.7%, and the fuel consumption is reduced by 0.48 liters per 100 kilometers. The EU Safety Certification (ECE R110) requires that high-pressure fuel delivery systems must be equipped with such safety redundancy devices.