Final Repot Fuel Tank

MANUFACTURING PROCESSES

BMM 2643

REPORT OF FUEL TANK

GROUP MEMBERS:

AHMAD WAQIYUDDIN ISMAT BIN MOHAMAD MH08056

MUHAMMAD ZULFADHLI BIN MD ZAKI MH08044

CHE MUHAMMAD RIDHWAN CHE HASHIM MH08049

AHMAD AZRIL BIN AZMI MH08060

MUHAMAD SOLEHIN BIN DAUD MH08059

SHAFRIQ HAFIZZAN BIN SALIM MH08050

LIM SING WEE MH08057

ATIQAH BINTI NAFSUN MH08048

BAGAVATHI A/P KRISHNAN MH08043

NUR IZZATI BT KHAIRUDDIN MH08041

Introduction or background information

Plastic fuel tanks have reached an amazing market share within the automotive industry during

the last decades. In addition to the classical blow moulding manufacturing process corresponding

thermoforming processes are considered in the recent time, too. Due to their great spatial

dimensions and complexity automotive fuel tanks are extraordinary articles with regard to

conventional thermoforming , and there is a real need for appropriate simulation tools including

all process stages within the industry. An important objective of such simulations is the

prediction of the resulting wall thickness distributions in dependency of the involved material

and manufacturing process parameters. Currently, the majority of plastic fuel tanks are blow

moulded, and corresponding blow moulding simulation tools are well available . Today,

alternative manufacturing processes for plastic fuel tanks are now under consideration, too.

Especially the twin sheet thermoforming process seems to offer a good approach for

implementing fuel system components into the fuel tank during manufacturing. One reason for

doing this is given by minimising air pollution and chemical emission due to external pipes and

vents, or by reducing the slosh motion by means of internal anti-sloshing-elements. For a detail

discussion of automotive sloshing issues, the reader may be referred to. The integration of

various fuel system components into the fuel tank shell could help to meet evaporative emission

standards. Especially this fact will be more important in the near future and represents challenge

for the automotive industry. Recently, the conversion of a blowmoulded fuel tank to a twin sheet

thermoforming process has been reported. These investigations made advantage of a

corresponding commercial simulation tool whose details have been published elsewhere. There

remain some unsolved questions with regard to such a process simulation approach. For

example, the influence of phase change behaviour and the temperature-dependency of the

material parameters is not understood sufficiently so far. The majority of the commercial

simulation packages assume constant thermal material parameters like density or heat

conductivity, or they do not taken into account the special temperature-dependency of the

specific heat due to the melting process. Since the rheological and the deformation behaviour are

strongly connected with the thermal behaviour, it becomes obvious that these issues affect

directly the accuracy of any simulation result.

An automotive fuel tank fabrication apparatus for forming through blow molding an

automotive fuel tank having a built-in part mounted in an interior thereof and an outer wall

formed from a thermoplastic synthetic resin, the automotive fuel tank fabrication apparatus

comprising:a blow mold for molding an outer wall of the automotive fuel tank; anda built-in part

holding unit for holding the built-in part at an opening and closing portion of the blow mold so as

to mount the built-in part within the automotive fuel tank, whereinthe blow mold has two molds

that can be opened and closed, and cavities are formed on opening and closing sides of the molds

for molding the automotive fuel tank, so as to hold a parison therebetween to mold an outer wall

of the automotive fuel tank, and whereinthe built-in part holding unit includes a plurality of

holding rods for holding the built-in part, the holding rods being made to freely advance and

retreat so as to hold the built-in part in a position where the built-in part confronts the cavities on

the opening and closing sides of the blow mold when the blow mold is opened, to position the

built-in part in an interior of the parison when the blow mold is closed and to retreat from the

blow mold after the parison is held, the holding rods being formed in such a manner as to reduce

their diameters as they extend towards distal ends thereof and adapted to be inserted into

insertion holes formed in the built-in part so as to hold the built-in part.

A fuel tank is safe container for flammable liquids and typically part of an engine system in

which the fuel is stored and propelled (fuel pump) or released (pressurized gas) into an engine.

The most common material that had been used to fabricate the fuel tank is aluminum. The main

concern with aluminum is oxidation pitting which will lead eventually to leaking. This can be

averted by applying a 16 - 18 mil exterior coating of coal tar epoxy, (about $50 per gallon), prior

to installation. Fuel tanks range in size and complexity from the small plastic tank of a butane

lighter to the multi-chambered cryogenic Space Shuttle external tank.

Economic

Historically, terne-coated steel (an 8% tin-lead coating) has been the mainstay for automotive

fuel tanks; however, several issues are changing the performance criteria that must be met and,

thus, threaten the application of steel products. In the performance attributes of the plastic and

steel alternatives are reviewed from an original equipment manufacturer (OEM) perspective in

the critical areas of manufacturability, cost, design, weight, safety, corrosion, and recyclability.

A comparative analysis of the various plastic and steel alternatives indicates that steel remains a

cost-effective material that meets all of the required performance criteria. A more specific cost

comparison of the new plastic tanks (i.e., multilayer or barrier coated) with the new steel tanks is

still required. Many of the drivers such as lead reduction, clean fuels, permeability, and weight

are a direct result of legislative and regulatory pressures.

Two main technologies are used to make fuel tanks:

Plastic high density polyethylene (HDPE) fuel tanks produced through blow molding.

This technology is increasingly used as it now shows its capacity to obtain very low

emissions of fuel (see Partial zero-emissions vehicle). HDPE can also allow for complex

shapes to be formed, this means the tank to be mounted directly over the rear axle, saving

space and improving crash safety. Initially there were concerns over the low fracture

toughness of HDPE, when compared to steel or aluminum. Concern for safety and long

term ability to function should be considered and monitored.

Metal (steel or aluminum) fuel tanks obtained by welding of stamped sheets. Although

this technology is very good in limiting fuel emissions, it tends to be less competitive and

thus less on the market.

Competitive Materials Analysis for Fuel Tanks

The comparative analysis of the performance attributes of the various plastic and steel

alternatives indicates that steel products still represent a cost-effective material that meets all the

required performance criteria of fuel tanks. Stainless steel tanks have been tested, and although

effective in flexible fuels, they are difficult to form without severe breakage occurring during

stamping. Also, stainless steel is expensive, with an estimated cost ratio to terne steel exceeding

5:1. The electrocoated zinc-nickel product is painted on both sides with an aluminum-rich

epoxy. Industry accelerated tests on the corrosion of painted zinc-nickel confirm that it will meet

a ten-year life in current fuels and flex-fuels and resist external corrosion. Testing the

characteristics of painted galvanneal (zinc-iron alloy coated steel) have found it effective for

resisting corrosion on both the inside and outside surfaces of the tank. Hot-dipped tin has also

been found to be effective for resisting all fuels, but it does require a paint coating for exterior

protection from road-induced corrosion. This product welds faster than painted terne and has a

better potential for good solderability than painted galvanneal and zinc-nickel coated steel

substrates, permitting the attachment of fuel filler tubes and other lines.

Plastic versus Steel

Manufacturing costs for either tank material seem conflicting, depending on the source.

Nevertheless, due to the invested capital of OEMs on stamping, welding, and assembly

equipment for metal tanks, their cost structure indicates a lower cost per piece on steel tanks

versus plastic ones, with the latter usually being outsourced (except for some Ford models).

Plastic tanks are formed by blowing a thick continuous tube of HDPE within a mold that

determines the final shape of the virtually seamless part, which could include the filler neck. The

blowing molds are cast from aluminum and cost considerably less than machined steel dies used

to stamp steel tanks. In general, four or more molds are integrated into one rotary style blow-

molding machine to achieve the desired productivity (i.e., one station blows while the other one

cools). Typically, the OEMs outsource the plastic tanks to various suppliers who bid for the

business. The plastic tank manufacturer also has to either chlorinate or fluorinate the plastic to

retard permeation, and both processes can be highly toxic if mishandled

Equipment and technology associated with the process/industry

Moeller Fuel Tank Technology

Engineered to look and perform better than any other fuel tank available, it’s easy to see why

Moeller is the name the marine industry thinks of first for innovative fuel tank technology.

Topside Fuel Tanks

• Provides positive seal with Moeller-exclusive injection molded 2-1/4" fill neck.

• Mechanically vented fuel cap ensures easy gripping with exclusive ribbed design that floats.

• Features 90°, 1/4 NPT fuel withdrawal elbow that rotates 360°eliminating a kinked fuel line

hose.

• Includes mechanical direct-sight gauge with easy-to-read indicator.

• Manufactured from high-density polyethylene with UV-stabilized resin.

• Tested to industry standard for USCG, NMMA, and ABYC.

• Specifically designed for use in Boston Whalers®, Carolina Skiff®and Key West®bench

style,center console, pontoon, deck and jon boat designs.

Portable Fuel Tanks

• Reserve fuel area designed into tank shell; tilt to access fuel.

• Mechanically vented fuel cap ensures easy gripping with innovative ribbed design that floats.

• Features 90°, 1/4 NPT fuel withdrawal elbow that rotates 360°eliminat-ing a kinked fuel line

hose.

• Includes mechanical direct-sight gauge with easy-to-read indicator.

• Manufactured from high-density polyethylene with UV-stabilized resin.

• Complies with industry requirements.

Below-Deck Technology with Moeller’s Above & Beyond Innovation

Unlike aluminum tanks, this comprehensive line of cross-linked polyethylene models is a

distinctive Moeller innovation: featuring corrosion/pit resistance and exclusive Moeller Tite™

pioneering. Each tank is complete with Hose Tite™, machined aluminum fill spouts, withdraw,

and vent fittings molded directly into the shell. Our tanks are your single source for the ultimate

in below-deck technology.

•Utilizes rotationally molded, cross-linked polyethylene plastic, allowing for complex shape

designs beyond

conventional and restricted aluminum tanks.

•Our fittings hold the highest O.D. and I.D. tolerances in the industry, ensuring you the highest

level of input flow available during tank refueling.

• Machined aluminum 3/8" withdraw fitting has 360°rotational capability for hook-up

convenience.

• Ideally suited for gasoline and diesel use with appropriate return kit (Part No. 035724-10).

• Helping you properly secure your tank, convenient hold down grooves molded directly into

tank shell work great with Moeller’s Permanent Fuel Tank Hold Down Kit(Part No. 035710).

• Conforms to all ABYC,NMMA and U.S. Coast Guard regulations.

• Available with CE certification.

1-Determine the type of machines to manufacture the component.

Fuel Tank Blow Molding Machine 

Description

This machine consists of extrusion system, continuous co-extruding die head, molding unit,

blowing unit, mechanical robot, frame, safety unit, central gravimetric feeding system, electric,

hydraulic and pneumatic control system. It is suitable for producing complex six layers plastic

fuel tank with strong barrier function or other blow containers with strong barrier function which

material is HMWHDPE for basic layer and EVOH or PA for barrier function layer. It can make

six layer 500L plastic container and upto 200L complicate shape auto fuel tank.

Features of plastic fuel tank

Plastic fuel tank has non-replaceable advantages compare with metal fuel tank in automobile

industry.

Plastic fuel tank is 30-50% lighter than same size metal fuel tank.

Plastic fuel tank has great free degree in oil tank shape design, which can fully utilize the active

space within automobile, so as to increase the stored oil volume of automobile.

Developing cycle for moulds for producing plastics fuel tank is shorter than that for die for

producing metal fuel tank, and its expense is less compare with metal fuel tank, which provide

convenience for designing manufacture ring and retrofitting automobile.

Compare with metal fuel tank, plastic fuel tank has incomparable advantages of high safety and

reliability, shock resistance, corrosion resistance, and unexploited performance, etc.

Basic Considerations For Material Selection:

Unless absolutely necessary, a Generic material should be selected.

Specifying a single manufacturer can limit availability and constrain prices.

Materials are constantly under development and as improvements are made grades

become obsolete and this requires the entire re-validation process to be undertaken on

established products.

Mould design considerations

Moulds mainly produced in Aluminium due to good thermal conductivity, weight saving, and

corrosion resistant.  Steel inserts are used in the working sections of the tool such as, pinch off

sections and blow pin areas where processing damage is most likley to occour.

Moulds will have a cooling channel, which is as near to the mould cavity as practical, a chilled

coolant is fed through to remove the heat from the plastic during the moulding cycle. The

volume of coolant is vitally important and therefore inlet and outlet pipes need to be as large as is

possible.

The mould will have guide pins and bushes to line the two mould cavities up during setting on

the press.

To inflate the parison we can incorporate a variety of blowing options; Fixed pin, Needle

blowing, Plunge Blowing, Moving calibrating pin, Stretching pins. Pre-blowing and main

blowing in a variety of combinations.

In mould cutting can be used to finish the product during the machine cycle, illuminating a

secondary finishing operation.

Invariably the surface finish in the mould cavity will be shot blasted with a fine shot blast.

This is to allow trapped air to escape on inflating the parison.

In very deep sections it will be necessary to provide special air vents.

Product design considerations

Designing products for the Blow moulding process requires some very fundemental parameters,

these are listed below. 

Ideally products benefit when symmetrical in design and shape.

The perfect shape being an ellipse to achieve optimum material wall thickness

distribution.

An even blowing ratio is preferred to optimise material distribution and preventing

localised thinning.

A suitable position is required to inject and exhaust the blowing air.

External dimension are easier to control, internal apertures may be affected by pinch off

formation.

Incorporate generous radii in all corners to minimise localised thinning.

Surface finish must be determined in the design stages usually a vapour blast finish on

HDPE for PVC highly polished surface is required.

Compression moulded threaded necks, lugs, bosses and live hinges can be formed in the

flash pockets and  in the line of draw of the tool.

Threaded necks can be compression formed and calibrated to give a finished neck.

When adapting products previously designed and produced from different processes it may be

necessary to compromise the original design to suit the Blow moulding process, the major

problems occouring when sharp detail is present.

All products must incorpurate material recycling instructions embossed in the most discrete

position on the product. Manufacturing date stamp for tracability is also important particulary on

products that may contain dangerous goods.

Blow moulding Equipment

The main components of a machine consist of a material feed unit, extruder, parison forming

device, blowing unit, and take out system.

The main types are:

Continuous Extrusion of Parison.

Accumulator Head to form parison.

Injection Blow moulding for PET production.

Main machine manufacturers. Kautex, Battenfeld, Techne, Graham, Bekum, Uniloy to name

just a few machines from the far east are becoming increasingly popular due to price constraints.

Blow moulding finishing

Moulded products can be finished using any combinations of the following.

Welding of brackets and handles using - Induction, Spin, Hot plate, and High Frequency

Welding.

Machining  by Routing, Drilling, Sawing.

Special purpose Fly knife cutting.

Finishing equipment is usually purpose built to accommodate the complexity of the product.

The Basic Process

1. A thermoplastic resin is heated to a molten state

2. It is then extruded through a die head to form a hollow tube called a parison.

3. The parison is dropped between two mold halves, which close around it.

4. The parison is inflated.

5. The plastic solidifies as it is cooled inside the mold.

6 .The mold opens and the finished component is removed.

2. What is suitable material for the component, give a reason?

Plastic

Plastic fuel tanks and system are designed to offer environment-friendly, cost-effective, lightweight, and safe solutions to the Automotive Industry.

Reason

Light-Weight Fuel Tanks

'Plastic tank systems also serve the dual purpose of decreasing the vehicle’s overall weight, as an average plastic tank weighs two-thirds less than an average steel tank.

'In an Environmental Protection Agency (EPA) comparison test of a steel and plastic fuel system for a 1996 GMT600 passenger van, a steel tank system weighed in at 21.92 kg (48.32 lbs.), while the plastic system weighed only 14.07 kg (31.02 lbs.).

In the EPA test, the lighter weight of the plastic fuel tank system resulted “in significant savings in use phase energy relative to the steel.” This contributes to an overall lower life cycle energy requirement for the plastic tank system, and a potential significant savings in fuel cost..

Cost-Effective Fuel Tanks

Plastics are generally perceived as cheap materials only used for mass production of low quality articles. Using plastics to produce this particular part of a car can be extremely cost-effective if we consider the complexity of its shape, its functional requirements (e.g. mecahanical and chemical resistance) and the quantity of material to be used.

Plastics can be processed at temperatures lower than steel or glass.

Corrosion resistance

If not properly protected fuel tanks can be seriously damaged through the corrosive action of their contents.

Plastic fuel tanks are made of a material which is resistant to corrosion itself: they therefore save the time and cost of coating

Environment-Friendly Fuel Tanks

Recyclability

Preventing waste from vehicles and promoting their re-use, recycling and other forms of recovery of vehicles and components has been the main objective of the Directive on End-of-Life Vehicles (ELV).

Plastic fuel tanks, in co-operation with other economic operators, have prepared to contribute to the achievement of the targets set by this Directive

Lower CO2 emissions

Through the weight reduction allowed by plastics, fuel tanks made of these materials can contribute to reduce fuel consumption and therefore CO2 emissions

Low Permeability

Plastic fuel tanks generally consist of a multilayered structure the permeability of which can be reduced in several ways. Using more layers, making them thicker or modifying their chemical composition may result in a structure which is heavier, more expensive and more difficult to recycle.

Even though a plastic fuel tank may become heavier according to the abovementioned methods, its weight would only increase by a small percentage; however this fuel tank would also still remain lighter than a tank made of steel.

Design Freedom

There are virtually no limits to the shapes that plastics can take but those of our imagination.

This makes plastic a material of choice to optimize space.

They make it possible to design fuel tanks that occupy all the space available around them, hence increasing the fuel storage capacity of the car and allowing more space for the passenger compartment.

Safety

When a plastic fuel tank is exposed to fire, it is more likely to melt or decompose and allow the contents to flow out and add fuel to the fire.

That reduces the risk of explosion and enhances the safety of the car.

Slosh noise-reduction

Car manufacturers keep making efforts to reduce most sounds produced by vehicles and which are often annoying for drivers and passengers.

If most of the sounds generally come from the engine, some also come from the fuel sender unit and from the fuel tank in which the fuel slosh was found to generate unpleasant noise.

Plastics can help reduce such sounds thanks to their insulating properties.

3. This company runs 24 hours non stop production. Assume there is no set-up time required. Therefore, based on your calculations, how many pieces can be produced in a month?

If company runs 24 hours non stop production

We assume:

45 pieces = 1 hour

24 hous = 45 x 24

= 1080 pieces per day

In 1 month;

1 month = 30 days

30 days = 720 hours

= 720 x 45

= 32400 pieces per month

ADVANTAGES AND DISADVANTAGES

Advantage of fuel tank

Steel

Terne-Coated Steel

o Advantages: Low cost at high volumes, recyclable, materials cost, and

permeability

Electrocoated Zn-Ni and Galvanneal

o Advantages: Low cost at high volumes, recyclable, effective inside and outside

corrosion protection, material cost, and permeability

Hot-Dipped Tin

o Advantages: Low cost at high volumes, recyclable, effective inside and outside

corrosion protection, material cost, permeability, and weldability

Stainless Steel

o Advantages: Corrosion, recycable, and permeability

Plastics

HDPE

o Advantages: Shape flexibility, low tooling costs at low volumes, weight, and

corrosion resistance

Multilayer and Barrier HDPE

o Advantages: Shape flexibility, low tooling costs at low volumes, weight,

corrosion resistance, and permeability

These plastic fuel tanks provide these advantages over fuels tanks of metal or other materials:

* Custom design and engineering, using Solid Works and 3D Solid Modeling

* Design flexibility and configured to customers requirements

* Large inventory of existing molds

* Uniform wall thickness

* Crosslink Polyethylene Resin (XLPE)

For fuel tanks of all types, gas and oil storage tank—to improve impact strength, provide higher stress crack resistance and enhance weatherability. (Contains a crosslinking agent that interacts in the molding cycle to form a crosslinked molecular structure that is ideal for gas and oil storage tanks, as well as trash containers and parts requiring maximum toughness or durability in cold temperatures. This material meets U.S. Coast Guard fire test requirements.)

* Impact strength

* Environmental stress-crack resistance

* UV stabilization for long-term outdoor protection

* Inserts and fittings able to be incorporated as integral components

* Internal vent tubes

* Integrally molded fill and vent

* Variety of colors and textures

* Mold-in graphics and embossing

* Economical tooling cost

* Hold down features

* Design-based testing—Fire test, shock test, pressure impulse test

* Three visual 100% inspections on all tanks

* 100% (3 psi) pressure check on all tanks

* Unique tool building techniques, developed by Inca, to assist in meeting design

specifications

* Product longevity

* Ready for installation

Plastic has many advantages over metal when used to create fuel tanks and other components:

* Lighter weight than most metal

(Plastic fuel tanks are 30% lighter than comparable metal tanks, also contributing to greater

fuel efficiency for the product.)Lighter weight than most metal

(Plastic fuel tanks are 30% lighter than comparable metal tanks, also contributing to greater

fuel efficiency for the product.)

* More durable

- One-piece seamless design is virtually indestructible.

(Seamed metal tanks can fracture and leak.)

- Greater impact strength provided.

- Material cannot rust.

- Plastic resists corrosion and damage from fuel additives.

- Longer life span ensured.

* Nonexplosive and safer than metal

(A metal tank can explode when it catches on fire.)

* Better compartment space utilization

(The shape or design of the product is less restricted by the material, so the plastic can conform easily to the shape required for the product and space availability. This feature saves on cost, size and weight of the component.)

* More convenient - (Installation can be easier.)

* Material transparency

(Use of translucent plastic allow content visibility, such as content level in a tank or gauge.)

* Low cost of material and production

Disadvantage of fuel tank

Boat fuel tank

The only disadvantage is that some of polyethylene fuel tanks cannot be used for storing

diesel fuel. Fuel tanks that are made up of fiberglass are not very popular. Though, they are not

affected by corrosion they are quite expensive and therefore cannot be found with every supplier.

If you are planning to go for a fiberglass tank then make sure to store ethanol-free gasoline if you

have purchased the units that have been manufactured before 1980. Avoid units made before the

mid-’80s unless you only use ethanol-free gasoline. Make sure to check the capacity of the fuel

tank before making the final decision.

Fuel tank

Competitive Materials Analysis for Fuel Tanks

Performance Attributes

Recyclability, safety, corrosion resistance in methanol fuels, and weight

Manufacturing Issues

Cost, formability/shape flexibility, weldability

Steel

Terne-Coated Steel

o Advantages: Low cost at high volumes, recyclable, materials cost, and

permeability

o Disadvantages: Shape flexibility, ineffective corrosion protection from methanol

fuel, lead-containing coating

Electrocoated Zn-Ni and Galvanneal

o Advantages: Low cost at high volumes, recyclable, effective inside and outside

corrosion protection, material cost, and permeability

o Disadvantages: Weldability and shape flexibility

Hot-Dipped Tin

o Advantages: Low cost at high volumes, recyclable, effective inside and outside

corrosion protection, material cost, permeability, and weldability

o Disadvantage: Shape flexibility

Stainless Steel

o Advantages: Corrosion, recycable, and permeability

o Disadvantages: Cost at all volumes, formability, and joinability

Plastics

HDPE

o Advantages: Shape flexibility, low tooling costs at low volumes, weight, and

corrosion resistance

o Disadvantages: High tooling costs at high volumes, high material cost,

permeability, and recyclability

Multilayer and Barrier HDPE

o Advantages: Shape flexibility, low tooling costs at low volumes, weight,

corrosion resistance, and permeability

o Disadvantages: Higher tooling costs at high volumes, higher material cost, and

harder to recycle

Plastic tank

A disadvantage to this though is that since plastic tanks have mechanical joints, when the

plastic distends due to continuous contact with vapors and liquids, the joints become vulnerable.

Some studies have shown that plastic gives the vehicle an advantage in terms of weight. Steel

tanks manufacturers however are developing ways to combat the criticism that steel tanks make

for heavier cars. Another safety issue is the ability of the tank to meet crash requirements.

Plastic tanks are seamless and this lack of seams makes it less vulnerable to failures during a

major crash. Even if they deform, plastic tanks can rebound back to its initial shape. Easily

allowing the fuel to permeate through. Not all plastic fuel tanks designed for boats are suitable

for storing either diesel or ethanol, so the type of fuel you use will determine whether a plastic

tank is suitable. Although plastic won't corrode as metal will over time, it can be puncture, which

heightens the risk of fuel fire.

Aluminium tank

Aluminium tanks could show signs of corrosion within a few years. Aluminium tanks should

not used be used for water because there is a possible link to Alzheimer’s disease when used for

drinking water tanks. Aluminium tanks have been know to crack at the welds when used in high

performance applications. Aluminium tanks need to be painted in a marine environment to

combat corrosion, painting adds to the cost and has to be checked and repainted when necessary.

Aluminium tanks needs to be earthed to the boat’s electrical system. Aluminium tanks need a

sender. Metal tanks cost more than polyethylene but are considered stronger. Many can hold

either diesel or gasoline. However, they often corrode and develop leaks. The thicker the

aluminum, the less corrosion and other problems occur. Stainless steel units have some of the

same problems

Corroded Aluminium Tank

Stainless steel

Stainless steel could show signs of corrosion within only a few years. Stainless steel tanks are

generally heavier if built from a reasonable thickness of material. They are difficult to form

without severe breakage occurring during stamping. Also, stainless steel is expensive, with an

estimated cost ratio to terne steel exceeding 5:1.Stainless steel tanks are quite often more

expensive if built by a reputable company. Stainless steel tanks need to be earthed to the boat’s

electrical system. Stainless steel tanks need a sender. Stainless steel tanks have been known to

crack at the welds when used in high performance applications.

Heavily corroded weld on stainless steel tank

Current processes and practices

Fuel Tank Material

The fuel tank shall be constructed of low carbon steel or corrosion resistant stainless steel. Non-

integral hardware may be constructed of other materials provided the material is durable and

suitable for its intended purpose.

Fuel Tank Color and Finish

The fuel tank shall be light in color to minimize heating of the fuel by radiant heat sources. Any

plating or paint materials shall not be degraded by contact with the fuel. A natural stainless steel

color is acceptable.\

PROCESS FOR MANUFACTURING A FUEL TANK AND TOOL FOR ITS

IMPLEMENTATION

Process for manufacturing a plastic fuel tank, the tank being

provided with at least one accessory connected to the internal

space of the tank via at least one orifice in the wall (14) of this

tank, said process comprising the steps consisting in supplying

a flexible film (12) and placing it on the tank so as to cover the

interface between the tank and the accessory, and welding the

film (12), preferably by means of laser radiation, over its entire

peripheral area, to the wall (14) of the tank. According to an

important aspect of the invention, before welding, a vacuum is

created between the flexible film (12) and the wall (14) of the tank using a vacuum tool having a

suction chamber comprising: - an opening directed towards both the flexible film and the

support, the opening in the suction chamber being peripheral and formed in such a way as to rest

over the edge of the flexible film over its entire periphery; and - at least one suction channel for

sucking out the air from the suction chamber.

PROCESS FOR PRODUCING A FUEL TANK WITH UNDER RIDE PROTECTOR

Abstract:

A fuel tank is produced together with an under ride protector in a blow-molding tool by a blow-

molding process. The under ride protector is held on the fuel tank by a form-locking connection

or by an integral connection. Therefore the outer under ride protector is connected to the fuel

tank in a simple production procedure

Procedure

1. A process for producing a fuel tank for a motor vehicle, the fuel tank having an under

ride protector on an outside, which comprises the steps of: placing a starting material of

the under ride protector together with a starting material of the fuel tank one on top of

another in a blow-molding tool; and deforming the starting material of the under ride

protector and the starting material of the fuel tank together by a blow-molding process in

the blow-molding tool to form the fuel tank with the under ride protector adapted to an

outer form of the fuel tank, the under ride protector is at a same time connected to the

fuel tank in the blow-molding tool by one of an integral connection and a form-locking

connection.

2. Wherein during the blow-molding process, forming the integral connection between the

under ride protector and the fuel tank in a number of contact zones by a residual process

heat of a blow-molded body.

3. which further comprises forming the starting material of the under ride protector with at

least one aperture; and filling the aperture with the starting material of the fuel tank

during the blow-molding process and the form-locking connection is formed between the

fuel tank and the under ride protector surrounding the fuel tank

4. A fuel tank system for a motor vehicle, comprising: an under ride protector formed of a

plastic material; and a fuel tank formed of a plastic material of a series of polyethylene

5. Wherein said plastic material of said under ride protector is a series of polypropylenes

with a glass fiber component.

6. A fuel tank system for a motor vehicle, comprising:a fuel tank; and an under ride

protector connected to said fuel tank locally at a number of points by means of an integral

connection

7. A fuel tank system for a motor vehicle, comprising: a fuel tank having projections; and an

under ride protector having apertures formed therein and disposed to correspond to said

projections on said fuel tank thus resulting in a form-locking connection between said

fuel tank and said under ride protector.

Future processes and practices

For a newly designed fuel tank assembly, the simulation of various physical tests and necessary

design changes before the prototype testing becomes important in vehicle development program

in order to control the development cost and time. The study of behavior of fluid in a fuel tank is

important aspect for ensuring minimum fluid turbulence in side the tank. This turbulence not

only creates noise while driving the vehicle, but also develops higer stresses due to impact of

fluid of tank structure.The sloshing phenomenon in a partially filled tank is observed when the

vehicle experiences sudden acceleration and deceleration. During the sloshing the fluid impacts

the tank walls which results in sloshing induced vibrations of the structure and the fuel which

causes the noise. In addition these fuel sloshing waves generatas the impact forces on the tank

structure. Also, sloshing phenomenon poses a challenge on the low fuel level management.

In view of this sloshing dynamics the following are the critical fuel tank design objectives.

1. Design of baffles to control the sloshing of the fuel.

2. Adequate structural integrity along with optimum weight and cost.

3. Design of tank shell and baffles for the low sloshing noise levels.

4. Design of baffles to aid for the low fuel level management.

For future scope, it is proposed to establish better correlation with the physical testing by further

refining of model parameters. Also, it is proposed to use the element pressure output on the tank

shell for calculation of response velocities and prediction of noise levels due to the sloshing of

the fuel. For example, General Motor's news that it plans to put the new Equinox fuel cell car on

the road next year. Green Car Congress has a story about General Motor's signing up Quantum

Fuel Systems Technologies Worldwide as its hydrogen fuel tank supplier. General Motor's 100

planned Equinoxes will get Quantum's tanks, which are made of lightweight materials and can

hold 10,000 psi of pressure. The tanks come with valves that monitor pressure and have safety

cutoffs, which would be activated if a crash is detected. Each Equinox will have three tanks,

holding 9.25 pounds of hydrogen. That's right, in the future we'll be measuring our fuel by the

pound, not by the gallon.

Application and product examples

Simple Shape Tanks

Cigar Shape Tank….

for the Renault LoganInergy - Courtesy of Renault

for the Fiat Grande Punto and the Alfaromeo MitoPlastic Components and Modules - Courtesy of Fiat

Saddle Tank System

for the Toyota HiluxInergy - Courtesy of Toyota

...AND SYSTEM  

for the Fiat Panda and CinquecentoPlastic Components and Modules - Courtesy of Fiat

COMPLEX TANK SYSTEM

for the Daimler C-ClassTI Automotive - Courtesy of Daimler

for the Audi Q5TI Automotive - Courtesy of Audi

PZEV Solution

100-Gallon Auxiliary Fuel Tank

The KSH 100-Gallon Auxiliary Fuel Tank, the largest gallon capacity of our standard sizes, is

designed to take up the least amount of bed space and still provide the maximum increase to your

fuel capacity with

out requiring

placards and

special

licensing. The tank

can be used as

either an auxiliary

diesel fuel tank or

an auxiliary gas

tank for the truck

bed. It is available in the standard and low profile models.  The picture at the right shows the

standard model 100-gallon Auxiliary Fuel Tank. The Low Profile and Standard Model tanks are

for Buick LucerneInergy - Courtesy of GM

made of .125 gauge polished aluminum diamond plate. Other options are available upon

request as outlined below.  KSH Auxiliary Tanks are made with two baffles to control fuel

sloshing and to provide added stability.  The Standard Model is designed to be bed height so that

it will not interfere with the operation of a 5th wheel. The Low Profile Model is designed to be

used with trucks that have special requirements such as tonneau covers and roll tops.

The KSH 100-Gallon Auxiliary Fuel Tank is designed to work in diesel models of Dodge, Ford,

and General Motors Trucks. The tank will work with either our Auxiliary Installation Kit or our

Transfer Installation Kit.

Stackable low permeation fuel tank

A marine fuel tank that is stackable due to matching protrusions and recesses on the top and

bottom and meets the new low hydrocarbon emission standard. In addition, the tank has side

recesses that match straps and a handle that is designed to lift and pour. The tank is generally

made from a polymer that has a hydrocarbon permeation of less than 15 g/sq. m/day.This fuel

tank invented by  Christopher Brown and Marvin Peplow. New federal government regulations

substantially tighten the amount of fuel a marine fuel tank such as those used with outboard

motors can emit into the atmosphere each day. U.S. Government rules for marine fuel system

hydrocarbon emissions are now 0.4 g/gallon/day for diumal venting from a fuel tank at 35.6

degrees C.; 1.5 g/gallon/day permeation from a fuel tank at 40 degrees C.; and 151 g/sq.

meter/day for hose and primer bulb permeation at 23 degrees C. (15 g/sq. meter/day with 15%

methanol blend fuel). A test fuel of 10% ethonol and 90% indolene can be used for normal

testing. Prior art fuel tanks emit considerably more hydrocarbons into the atmosphere than this. It

would be advantageous to have a fuel tank made from regular or treated polymer material that

can be stacked with other similar tanks for packaging and shipping and that has some sort of

recess for straps. 

Space Shuttle External Tank (ET)

A Space Shuttle External Tank (ET) is the component of the Space Shuttle launch vehicle that

contains the liquid hydrogen fuel and liquid oxygen oxidizer. During lift-off and ascent it

supplies the fuel and oxidizer under pressure to the three space shuttle main engines (SSME) in

the orbiter. The ET is jettisoned just over 10 seconds after MECO (Main Engine Cut Off), where

the SSMEs are shut down, and re-enters the Earth's atmosphere. Unlike the Solid Rocket

Boosters, external tanks have not been re-used. They break up before impact in the Indian

Ocean (or Pacific Ocean in the case of direct-insertion launch trajectories, which are currently

utilized) away from known shipping lanes.Although the external tanks have always been

discarded, it is possible to take them into orbit and re-use them. Plans for re-use have ranged

from incorporation into a space station as extra living or research space, as rocket fuel tanks for

interplanetary missions (e.g. Mars), to raw materials for orbiting factories.

Other Plastic Fuel Tank Applications

Typical industries served include:

* Agriculture

* Automotive

* Concrete

* Construction

* Forestry

* Industrial equipment

* Lawn and garden

* Materials handling

* Off-road vehicles

* Outdoor power equipment

* Recreational vehicles

* Utility vehicles

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