Actuator module for an injector, vehicle with an actuator module and method for manufacturing an actuator module

Abstract

The present invention relates to an actuator module for an injector, comprising a recess in a housing of the actuator module, wherein a separating element is slidably arranged in the recess, which is configured to separate a first space in the recess from a second space in the recess in a substantially fluid-tight manner, wherein the separating element is slidably arranged to adapt a first volume of the first space and / or a second volume of the second space, wherein the actuator module comprises a spring element which is configured to exert a predetermined force on the separating element, and wherein the actuator module is configured to set a predetermined pressure in a first liquid in the first space by means of the separating element and the spring element.

Description

State of the art

[0001] The present invention relates to an actuator module for an injector, a vehicle and a method for producing an actuator module.

[0002] Currently, there are a variety of different solutions for storing actuators in fluids separate from the fuel being injected in gas injectors. Due to the increasing efficiency requirements for actuators and gas injectors, the need for innovative and robust injector concepts is continuously growing.

[0003] The constant weight reduction in the vehicle sector to reduce fuel consumption as well as increasing competition are creating cost pressure, so that cheaper and more efficient components for vehicles are in greater demand. Disclosure of the invention

[0004] The actuator module according to the invention for an injector with the features of claim 1 has the advantage over the known device that the actuator module has a sub-volume filled with liquid, essentially free of gas, and that a change in the volume of the hydraulic fluid within the scope of expected temperature fluctuations nevertheless does not lead to an unacceptable pressure increase or unacceptable gas formation in the sub-volume filled with liquid. Thus, the area of ​​the actuator is always homogeneously filled with liquid, allowing hydraulic damping elements to function reliably. Furthermore, the operating life of the actuator module or the injector can thus be further increased.

[0005] This is achieved according to the invention in that the actuator module for an injector has a recess in a housing of the actuator module. A separating element is displaceably arranged in the recess, which separating element is designed to separate a first space in the recess from a second space in the recess in a substantially fluid-tight manner, wherein the separating element is displaceably arranged in such a way as to adapt a first volume of the first space and / or a second volume of the second space, wherein the actuator module has a spring element which is designed to apply a predetermined force to the separating element, wherein the actuator module is designed to set a predetermined pressure in a first liquid in the first space by means of the separating element and the spring element.

[0006] In other words, the first chamber of the actuator module is filled with a liquid, which is subjected to a force by the separating element and the spring element, whereby a desired pressure is established in the liquid. A separating element can be displaceably arranged in a recess in a housing of the actuator module. In particular, the separating element can have a sealing element for the wall in the recess. More preferably, the separating element is arranged displaceably or displaceably in order to be able to provide a change in the volume of the first chamber as well as a change in the volume of the second chamber. More preferably, the actuator module has a spring element, which can be connected, for example, to a wall in the recess of the housing or the like, so that a spring force can be exerted on the separating element.The spring action is adjusted in particular such that the fluid in the first chamber is pressurized, since the spring element displaces or deflects the separating element to reduce the volume in the first chamber. The predetermined pressure can be selected in particular such that it lies above the vapor pressure of the first liquid in the first chamber throughout the entire permissible temperature range. This preferably reliably prevents outgassing of the first liquid in the first chamber, thus ensuring reliable operation of the actuator module or injector at all times.

[0007] The subclaims show preferred developments of the invention.

[0008] Further preferably, the predetermined pressure is selected such that the first liquid is substantially free of gaseous influences.

[0009] An advantage of this embodiment is that the operating time of the actuator module can be further increased since the filling level of the first space with the first liquid is 100%, since temperature influences on the actuator module can be compensated by means of the spring element and the separating element.

[0010] Preferably, the separating element has at least one sealing element, wherein the sealing element is designed to form a fluid-tight connection between a wall in the recess and the separating element.

[0011] An advantage of this embodiment is that no liquid flows from the first space into the second space or the like, so that the overall operating time of the actuator module can be further increased.

[0012] Preferably, the second space is configured to form and / or absorb a vacuum.

[0013] An advantage of this embodiment is that if the volume of the liquid in the first chamber changes, which leads to a volume change in both the first and second chambers, no pressure change can occur in the second chamber, and thus no undesirable influence of the pressure in the second chamber on the pressure in the first chamber can occur. A further advantage of this embodiment is that no gas can pass from the second chamber into the first chamber between the sealing element and the wall of the recess, making it easier to ensure gas-free filling of the first chamber over its service life.

[0014] Preferably, the second space is designed to accommodate a gaseous fluid.

[0015] An advantage of this embodiment is that the pressure difference that the sealing element can exert on the separating element is reduced compared to the formation of a vacuum in the second space.

[0016] Preferably, the gaseous fluid in the second space is air.

[0017] The advantage of this embodiment is that during the filling process, the suction of air from the second space and the filling of the second space with a fluid other than air can be omitted.

[0018] Further preferably, the actuator module has a first extension direction, wherein an orientation of the predetermined force of the spring element and the first extension direction are substantially parallel.

[0019] An advantage of this embodiment is that the force can be transmitted from the spring to the separating element and from there to the liquid in the first chamber without additional deflections.

[0020] Further preferably, the spring element is designed to compensate for a volume change of the first liquid of up to 25% while maintaining the predetermined pressure.

[0021] An advantage of this embodiment is that the actuator module remains usable both at low outside temperatures and at high outside temperatures and the liquid in the first chamber is free of gas inclusions.

[0022] Further preferably, the actuator module has a stop element, wherein the spring element presses the separating element against the stop element when the first space is at least partially free of the first liquid.

[0023] An advantage of this embodiment is that the assembly process or the filling process of the actuator module is simplified because the separating element is pressed against the stop element in its initial position and the spring element thus has a desired preload even before filling.

[0024] Further preferably, the separating element has an end face which is in contact with the first liquid substantially over its entire surface, wherein a travel path of the separating element and / or a deflection of the spring element is adapted as a function of the end face.

[0025] An advantage of this embodiment is that the separating element can be adapted to the respective actuator module or to a specific application scenario of the actuator module by adjusting the end face, particularly the face in contact with the first fluid. This allows the range of motion and the preload force of the spring element to be varied at a given fluid pressure in the first chamber and adapted to the structural constraints.

[0026] A further aspect of the invention relates to a vehicle having an actuator module for an injector as described above and below.

[0027] A further aspect of the invention relates to a method for producing an actuator module as described above and below, which comprises the steps: - Forming a first vacuum in a first space of the actuator module, which is at least partially formed by a spring-mounted separating element, - Filling the first space with a first liquid so that a predetermined pressure is present in the first space, wherein the separating element is at least partially deflected.

[0028] An advantage of this embodiment is that the first space is free of air or other interfering elements, so that a defined fluid pressure is built up in the first space and can be specifically specified by means of the spring element and the separating element.

[0029] More preferably, the method further comprises the step: - Forming a second vacuum in a second space of the actuator module, which is partially formed by the spring-mounted separating element.

[0030] An advantage of this embodiment is that, if a vacuum is also formed in the second space, apart from the predetermined force provided by the spring element, no further force dependent on the pressure in the second space is exerted on that end face of the separating element which may face the second space.

[0031] Further preferably, the first vacuum and the second vacuum are formed substantially simultaneously.

[0032] An advantage of this form of training is that the vacuums can be formed simultaneously in one production step, thus significantly reducing the cycle time for manufacturing the actuator module.

[0033] More preferably, the method further comprises the step of closing a bore in the first space and / or a bore in the second space.

[0034] An advantage of this embodiment is that once the first liquid, or a correct amount of the first liquid, has been introduced into the first chamber, the first chamber can be sealed, for example, by welding. More preferably, the second chamber can be sealed at the same time, preventing contamination or the like from entering the second chamber.

[0035] More preferably, the sealing is carried out by means of a laser welding process.

[0036] An advantage of this form of training is that the laser welding process can be integrated into a production station, for example through a lens or similar, so that transporting the actuator module to another production station is not necessary.

[0037] Further preferably, the method comprises the step: - Filling a second chamber of the actuator module, which is at least partially formed by the spring-loaded separating element, with a fluid.

[0038] An advantage of this embodiment is that if the second space is filled with a fluid, this can be designed in such a way that the risk of oxygen entering or possible corrosion in the second space is significantly reduced. Short description of the drawings

[0039] Embodiments of the invention are described in detail below with reference to the accompanying drawings. In the drawing: Fig. 1 an injector with a schematically indicated area of ​​an actuator module, Fig. 2 to 15 an actuator module for an injector according to various embodiments, Fig. 16 a symbolic vehicle according to an embodiment and Fig. 17 and Fig. 18 is a flowchart illustrating steps of the method according to an embodiment. Embodiments of the invention

[0040] Preferably, in all figures, all identical components, elements and / or units are provided with the same reference numerals.

[0041] Fig. 1 shows an injector 100 with a schematically indicated region of an actuator module 10 according to one embodiment. The injector 100 can be a hydrogen injection valve for hydrogen combustion engines. The actuator module 10 can be an actuator such as a solenoid actuator with a plunger, which, when actuated, deflects a valve needle so that the injection valve opens. A region 101 of the injector 100 can be filled with a liquid. By means of the actuator module 10, the region 101 of the injector 100 can be substantially free of gas inclusions or the like and can take into account the different density of the liquid at different operating temperatures. By means of the actuator module 10, corrugated bellows or the like can be dispensed with.

[0042] Fig. 2 shows an actuator module 10 according to one embodiment. The actuator module 10 for an injector 100 has a recess 11 in a housing 13 of the actuator module 10. A separating element 12 is displaceably arranged in the recess 11. A first space 14 and a second space 16 are provided in the recess 11. More preferably, the separating element 12 separates the first space 14 from the second space 16. More preferably, a volume change of the first space 14 or the second space 16 can be permitted by displacing the separating element. The actuator module 10 preferably has a spring element 18, which is configured to exert a predetermined force on the separating element 12. The actuator module 10 is configured to set a predetermined pressure in a liquid in the first space 14 by means of the separating element 12 and the spring element 18. As in the Fig. 1, the separating element 12 has two sealing elements 20, which in particular form a fluid-tight connection between a wall 22 of the recess 11 and the separating element 12.

[0043] Fig. 3 shows an actuator module 10 according to an embodiment. Fig. 3, the actuator module 10 is shown in an unfilled state. The actuator module 10 has a first extension direction 24, which extends in particular along the first space 14. Further preferably, a displacement direction of the separating element 12 is parallel to the first extension direction 24. Further preferably, the spring element 18 forms a force having an orientation 26. Further preferably, the orientation 26 is substantially parallel to the extension direction 24. Further preferably, the actuator module 10 has a stop element 28, wherein the spring element 18 presses the separating element 12 against the stop element 28, while the first space 14 is at least partially free of the first liquid.

[0044] Further preferably, the housing 13 of the actuator module 10 has a first bore 36 which connects the first space 14 with the environment and a second bore 38 which connects the second space with the environment.

[0045] Fig. 4 shows the actuator module 10 according to one embodiment. The actuator module 10 as shown in the Fig. 4, is connected to a production system 400. The production system 400 has an oil pump 402 and a vacuum pump 404. The production system 400 has a three-way valve 406. Furthermore, the production system 400 has a supply line 408, which is configured both to create a vacuum in the first chamber 14 and to fill the first chamber 14 with the first liquid. Further preferably, the production system 400 has a second supply line 410, which is configured to create a vacuum in the second chamber 16 of the actuator module 10.

[0046] Fig. Figure 5 shows the actuator module 10 according to one embodiment. The actuator module 10 is sealed by two sealing units 412, 414 of the production system 400. Thus, the vacuum pump 404 can create a vacuum essentially simultaneously in both the first chamber 14 and the second chamber 16.

[0047] Fig. 6 shows the actuator module 10 according to an embodiment. The actuator module 10 or the first chamber 14 of the actuator module 10 is shown in the Fig. 6 is filled with the first fluid by means of the oil pump 402. For this purpose, the three-way valve 406 is switched so that the oil pump 402 and the first chamber 14 are connected to each other.

[0048] Fig. 7 shows the actuator module 10 according to an embodiment. Fig. 7, a predetermined pressure is set in the first chamber 14 of the actuator module 10 by means of the oil pump 402 by filling it with the first fluid. In this case, the separating element 12 is preferably deflected from the stop element 28 by the pressure in the first chamber until an equilibrium exists between the deflecting hydraulic force and the restoring spring force of the spring element 18.

[0049] Fig. 8 shows the actuator module 10 according to a. The actuator module 10 in the Fig. 8 has already been filled with a first liquid in the first chamber 14, so that the separating element 12 is deflected along a travel path 32. Furthermore, the spring element 18 has a deflection 34 that is smaller than when the first chamber 14 is not filled with the first liquid. In particular, the travel path 32 can be adjusted depending on the end face 30 of the separating element 12.

[0050] Fig. Figure 9 shows the actuator module 10 according to one embodiment. The actuator module 10 preferably has a gaseous fluid in the second chamber 16. Particularly preferably, the gaseous fluid in the second chamber is air.

[0051] Fig. 10 shows the actuator module 10 according to one embodiment. The actuator module 10 is prepared for use using a production system 400. The production system 400 has only a single inlet / outlet 408. Thus, the second chamber 16 cannot be subjected to a vacuum, but remains filled with ambient air. The actuator module 10 can be secured against the sleeve 411 of the production system 400 with sealing units 412, 413.

[0052] Fig. 11 shows the actuator module 10 according to an embodiment. Fig. 11, the vacuum pump 404 creates a vacuum in the first chamber 14. The three-way valve 406 can establish a connection between the first chamber 14 and the vacuum pump 404.

[0053] Fig. 12 shows the actuator module 10 according to one embodiment. As shown in the Fig. As shown in Figure 12, the three-way valve 406 now has a connection between the oil pump 402 and the first chamber 14. Thus, the oil pump 402 can fill the first chamber with a first fluid.

[0054] Fig. Figure 13 shows an embodiment of the actuator module 10. The oil pump 402 can be connected to the first chamber 14 via the three-way valve 406. The oil pump 402 can thereby create a predetermined pressure in the first chamber 14 with the first fluid. The separating element 12 is then deflected against the spring element 18.

[0055] Fig. 14 shows an embodiment of the actuator module 10. The actuator module 10 was filled with a first liquid in the first chamber 14, in particular such that a predetermined pressure is created in the first chamber 14 by means of the first liquid in the separating element 12 and the spring element 18. A first bore 36, providing access to the first chamber 14, and a second bore 38, providing access to the second chamber 16, were sealed, in particular by laser beam welding.

[0056] Fig. 15 shows an embodiment of the actuator module 10. In Fig. 15, the supply line 14 is preferably not as in Fig. 3 is permanently connected to the vacuum pump 404, but the production device additionally has a container 405 which is filled with a gaseous fluid and a further

[0057] Three-way valve 407, via which the supply line 410 can be optionally connected to the vacuum pump 404 or the container 405. The production system is preferably additionally capable of filling the second chamber 16 of the actuator module 10 with a gaseous fluid.

[0058] Fig. 16 shows a vehicle 200 according to one embodiment. The vehicle 200 includes an actuator module 10 as described above and below. Furthermore, the vehicle 200 may include an injector 100 in which the actuator module 10 may be used.

[0059] Fig. 17 shows a flowchart illustrating an embodiment of the method 300. The method 300 for producing an actuator module 10 as described above and below comprises the steps: - Forming S1 a first vacuum in a first space 14 of the actuator module 10, which is at least partially formed by a spring-loaded separating element 12, - Filling S2 of the first space 14 with a first liquid so that a predetermined pressure is present in the first space 14, wherein the separating element 12 is at least partially deflected. - Preferably, the also in Fig. 15 shown step of closing S3 of a first bore 36 of the first chamber 14.

[0060] Fig. 18 shows a flowchart illustrating the method 300 according to an embodiment. The method 300 comprises the same steps S1 and S2 and preferably S3 as already described with regard to the Fig.17. Furthermore, the method 300 comprises a step S4 of forming a second vacuum in a second chamber 16 of the actuator module 10, which is formed at least partially by the spring-loaded separating element 12. The step S4 can advantageously take place simultaneously with the step S1 and be combined with it into a single process step. More preferably, the method 300 comprises a further step S5 of filling the second chamber 16 with a gaseous fluid. Furthermore, the method 300 comprises the step S6 of closing a second bore 38 to the second chamber 16.

Claims

[1] Actuator module (10) for an injector (100), comprising a recess (11) in a housing (13) of the actuator module (10), wherein a separating element (12) is displaceably arranged in the recess (11), which separating element is designed to separate a first space (14) in the recess (11) from a second space (16) in the recess (11) in a substantially fluid-tight manner, wherein the separating element (12) is displaceably arranged in such a way as to adapt a first volume of the first space (14) and / or a second volume of the second space (16), wherein the actuator module (10) has a spring element (18) which is designed to apply a predetermined force to the separating element (12), wherein the actuator module (10) is designed to maintain a predetermined pressure in a first liquid in the first space (14) by means of the separating element (12) and the spring element (18). [2] Actuator module (10) according to claim 1, wherein the predetermined pressure is selected such that the first liquid is substantially free of gaseous inclusions. [3] Actuator module (10) according to one of the preceding claims, wherein the separating element (12) has at least one sealing element (20), wherein the sealing element (20) is designed to form a fluid-tight connection between a wall (22) of the recess (11) and the separating element (12). [4] Actuator module (10) according to one of the preceding claims, wherein the second space (16) is adapted to form and / or receive a vacuum. [5] Actuator module (10) according to one of claims 1-3, wherein the second space is adapted to receive a gaseous fluid. [6] Actuator module (10) according to claim 5, wherein the gaseous fluid is air. [7] Actuator module (10) according to one of the preceding claims, wherein the actuator module (10) has a first extension direction (24), wherein an orientation (26) of the predetermined force of the spring element (18) and the first extension direction (24) are substantially parallel. [8] Actuator module (10) according to one of the preceding claims, wherein the spring element (18) is designed such that it compensates for a volume change of the first liquid of up to 25% while maintaining the predetermined pressure. [9] Actuator module (10) according to one of the preceding claims, wherein the actuator module (10) has a stop element (28), wherein the spring element (18) presses the separating element (12) against the stop element (28) when the first space (14) is at least partially free of the first liquid. [10] Actuator module (10) according to one of the preceding claims, wherein the separating element (12) has an end face (30) which is substantially completely in contact with the first liquid, wherein a travel path (32) of the separating element (12) and / or a deflection (34) of the spring element (18) is adapted as a function of the end face (30). [11] Vehicle (200) comprising an actuator module (10) for an injector (100) according to one of the preceding claims. [12] Method (300) for producing an actuator module (10) according to one of claims 1 to 10, comprising the steps: - forming (S1) a first vacuum in a first space (14) of the actuator module (10), which is at least partially formed by a spring-mounted separating element (12), - filling (S2) the first space (14) with a first liquid so that a predetermined pressure is present in the first space (14), wherein the separating element (12) is at least partially deflected. [13] The method (300) of claim 12, further comprising the step: - Closing (S3) a first bore (36) to the first chamber (14). [14] Method (300) according to one of claims 12 and 13, further comprising the step: - Forming (S4) a second vacuum in a second space (16) of the actuator module (10), which is at least partially formed by the spring-mounted separating element (12). [15] The method (300) of claim 14, wherein the first vacuum and the second vacuum are formed substantially simultaneously. [16] Method (300) according to one of claims 12 to 15, further comprising the step: - filling (S5) a second chamber (16) of the actuator module (10), which is at least partially formed by the spring-mounted separating element (12), with a fluid. [17] Method (300) according to one of claims 12 to 16, further comprising the step: - Closing (S6) a second bore (38) to the second chamber (16). [18] Method (300) according to one of claims 13 and 17, wherein the closing (S3, S6) is carried out by means of a laser welding process.

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