Voltage fluctuations directly affect the output stability of the fuel pump. Test data shows that the voltage of the ordinary vehicle’s circuit system may fluctuate by ±1.5 volts under idle conditions, resulting in a fuel pump flow deviation of up to 12%. After installing a PWM controller with adjustable duty cycle ranging from 10% to 100%, the standard deviation of fuel pressure dropped from 0.38 bar to 0.12 bar, and the fluctuation range of air-fuel ratio narrowed by 67%. The 2022 MotoIQ test report confirmed that in a fault scenario where the simulated voltage dropped to 10.5 volts, the controller ensured that the fuel pump maintained a constant pressure of 4.5 bar, avoiding the risk of engine failure.
The problem of excessive wear of the fuel pump deserves attention. Laboratory bench experiments show that under the direct power supply mode, the average annual operating temperature of the oil pump motor reaches 88℃, and the carbon brush wear rate is 0.15 millimeters per 10,000 kilometers. After installing the active temperature control controller, the motor temperature is stabilized at the safety threshold of 65℃ by reducing the duty cycle by 70%. Combined with the speed matching algorithm, the annual wear of carbon brushes is reduced by 56%. Statistics from the Porsche Owners’ Forum show that the fuel pump failure rate of 997 series models equipped with controllers has dropped from 23% per 100,000 kilometers to 7%.
The economic efficiency of energy consumption has been significantly improved. In dynamic flow testing, the traditional oil pump wastes 63% of electrical energy to generate heat at idle speed, while the closed-loop controller intelligently adjusts the output based on the manifold pressure signal, compressing the proportion of ineffective work to 18%. Actual road test data shows that vehicles equipped with controllers can save 0.65 liters of fuel per 100 kilometers. Calculated based on an average annual driving distance of 15,000 kilometers, the cost of the controller equipment can be recovered within 12 months. An empirical study published in Automotive Engineering in 2019 pointed out that this scheme reduced the load of the power management system of hybrid vehicles by 19 amperes.
System security protection cannot be ignored. When the fuel pressure sensor detects that the pressure drop exceeds 1.2 bar within 4 seconds, the intelligent controller automatically triggers the pressure release protection and lights up the fault code. Compared with the fuse blowing solution, the response speed is improved by 300 milliseconds. Accident analysis by the National Highway Traffic Safety Administration (NHTSA) of the United States shows that such designs have reduced the probability of accidents caused by fuel injection system failures by 41%. Modern integrated controllers are more equipped with CAN bus communication capabilities, transmitting 128 sets of diagnostic data to the ECU per second to achieve millisecond-level fault prediction.
Data from the modification parts market shows that after installing a professional controller, the lifespan of the fuel pump assembly has been extended to 280,000 kilometers, an increase of 82% compared to the direct drive mode. Especially for the dual-pump parallel system, the controller eliminates the pulse oscillation with a peak pressure interference of 2.3 bar through a phase offset control within 0.01 seconds. The actual test report from the BMW M Series certified modification factory confirmed that this solution has increased the fuel system stability index of the 800-horsepower turbocharged engine by 74%, and the risk rate of fuel cut-off at high RPMS is approaching zero.