Modern trucks with large fuel tanks often carry up to 20% unusable fuel—called “dead volume”—because fuel near the bottom of the tank can be contaminated with dirt or air bubbles. Sucking in this fuel can damage the engine, so it’s left unused. To solve this, newer trucks use a fuel optimization unit that minimizes waste and pumps almost all the fuel to the engine. However, the exposed electronics and pumping mechanisms of this system are vulnerable. They’re easily damaged by accidental stepping during maintenance or by weather like rain, sun, and dust—leading to costly repairs.
The Solution
This invention introduces a protective cover for the fuel optimization unit made from strong, corrugated sheet metal shaped like a “J.” It shields both the electronic and pumping components from physical impact and environmental damage. A smart addition is the option to plug the front of the unit for even more protection.
What Makes It New
Unlike existing fuel tank protectors, which often double as ladders or only shield the tank itself, this design focuses on protecting the sensitive optimization unit—a high-cost, high-value part. Its “J” shape fits snugly over the unit, blocking physical contact and shielding the critical wiring and electronics.
Tangible Benefits
- Prevents damage from accidental stepping or environmental exposure
- Reduces repair costs for a unit worth up to R$60,000
- Easy to install on both new and used trucks
- Also serves as a safe step surface for drivers and mechanics
Broader Impact
By protecting this essential fuel-saving technology, the invention ensures that trucks waste less fuel and operate more efficiently. This means lower emissions, reduced fuel costs, and longer-lasting equipment—benefits that ripple through the transportation industry and support sustainability.
Conclusion
This protector is a smart, affordable upgrade that preserves critical equipment, cuts costs, and helps the environment—a simple yet impactful innovation for the trucking industry.