In rugged terrain, the power system stability of the vehicle depends entirely on the Fuel Pump reliability. Take the example of the third-generation electronic fuel pump made with high-strength alloy materials. Its anti-vibration capability has been increased by 42% in comparison with the traditional model. It can operate continuously for more than 1,500 hours in a harsh environment with an amplitude of more than 5.3 millimeters and a frequency of 25 Hz, and the failure rate is less than 0.8%. For instance, the specially designed Fuel Pump installed by Great Wall Motor on the 2022 Dakar Rally ran smoothly during the desert stage with an average inclination of 37° and an altitude difference of more than 2,000 meters. The race fuel flow was maintained constant at 12.5 liters per minute with an error margin of ±1.2%, which supported the team’s completion percentage up to 89%.
With regard to pressure tolerance, the Fuel Pump model with a multi-stage centrifugal turbine can supply stable fuel pressure even under severe loads. Experimental results show that during a sudden rise in the outside temperature from -30℃ to 65℃, the fluctuation of the internal oil pressure is only ± 0.05MPa, which is significantly lower than the industry standard specified at ± 0.15MPa. Sany Heavy Industry affirmed in the plateau engineering vehicle tests on the Qinghai-Tibet Plateau that the Fuel Pump with the intelligent temperature control valve could supply a power output of over 98% at an altitude of 5,000 meters and an oxygen concentration of merely 12%, and its fuel efficiency was increased by 22% over the previous generation. Besides, the true test of Toyota Hilux with the muddy road conditions during the rainy season in Africa shows that its anti-corrosion coating on the Fuel Pump extends the life span of key components to 8 years, reduces sediment intrusion by 76%, extends the maintenance cycle from 30,000 kilometers to 50,000 kilometers, and saves 3,200 yuan in maintenance costs per vehicle annually.
Under the effect of dynamic impact, the Fuel Pump‘s strength in structure and sealing technology are very crucial. According to the simulation test of SAE J1455 standard, after making the Fuel Pump of a certain German enterprise experience the impact of instantaneous acceleration of 15G, the fuel leakage was less than 0.03 milliliters per minute and the deformation rate of the sealing ring was less than 1.5%. Statistics provided by the North American Trucking Association in 2023 indicate that the failure rate of Fuel Pumps with carbon fiber reinforced shells on gravel roads is only one-third of that of standard aluminum shells. The fleet’s yearly downtime due to faults is reduced by 45 hours, and the resulting revenue of transport companies is increased by 7.4%. On the Brazilian mining giant Vale’s mining trucks, the Fuel Pump’s redundant dual-pump system design reduces the emergency failover time to 0.8 seconds, ensuring uninterrupted fuel supply during heavy-load climbing, and reducing the project payback time from 14 months to 9 months.
The data also indicates that the optimized Fuel pump can reduce the fuel loss rate in challenging terrains. For example, the upgraded high-pressure Fuel Pump of the Jeep Wrangler Rubicon car achieves 0.1 millisecond precision in fuel injection pulse width control while climbing a 35° rock slope. The air-fuel ratio fluctuation range is lowered from ±0.8 to ±0.3, and fuel consumption every 100 kilometers is lowered by 1.7 liters. According to the Frost & Sullivan report, the global Fuel pumps for off-road vehicles size will be 4.7 billion US dollars in 2025. Among them, the compound annual growth rate of weather-resistant modules is 11.3%, and the fourth-generation products based on ceramic bearings and adaptive algorithms will occupy 38% of the high-end market share and be the technical standard for withstanding extreme terrains.