Alignment systems and methods

Abstract

An alignment system includes an optical sensor device that can be inserted into a passageway of a body located between a fuel injector and a combustion chamber of an engine cylinder. The body is shaped to deliver fuel ejected from an injection orifice in the fuel injector to the combustion chamber of the engine cylinder. The system also includes a controller that can examine the output of the optical sensor device and determine, based on the output from the optical sensor device, whether the passageway of the body is aligned with the injection orifice of the fuel injector. The controller can change the position of one or more of the body or the fuel injector in response to determining that the passageway of the body is misaligned with the injection orifice of the fuel injector.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 152,665 (filed February 23, 2021), the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] The topics described in this article relate to alignment systems and methods for fuel flow and fuel pathways. Background Technology

[0004] An injection insert is mounted below the fuel injector in the engine cylinder head assembly. The injection insert contains an inlet for receiving fuel from the fuel injector. Fuel is transferred to a fuel passage that extends through and exits the insert. An additional air or gas passage allows air or other gases to flow into the insert (from outside the insert), where the fuel entrains air from inside the insert to form a fuel-air mixture. The fuel-air mixture exits the insert and enters the combustion chamber of the engine cylinder. This can result in a longer mixing time, enhanced combustion, and lower emissions.

[0005] The fuel injector sprays fuel from the injector orifice into the corresponding passage. Alignment with the inlet is necessary. This alignment can be about centering the fuel flow and the fuel passage within the injector insert. If misaligned, fuel may be blocked from reaching the combustion chamber (thus preventing combustion in the cylinder). Alternatively, if misaligned, the fuel injection may impinge on the edge of the injector inlet. This can cause poor fuel atomization or loss of injection momentum, resulting in poor or inconsistent combustion within the combustion chamber.

[0006] One technique for aligning one or more internal passages of an insert relative to the injection orifice of a fuel injector involves inserting a small drill bit or a small-diameter wire into the injection orifice of the fuel injector. The fuel injector is rotated until the drill bit or wire is received in the center of the passage of the insert. One problem with this technique is that the drill bit or wire may break during rotation of the fuel injector, thereby damaging the fuel injector. Another technique for aligning the insert passage with the fuel injector injection orifice involves installing a nylon plug into the insert passage. The fuel injector is then controlled (e.g., started) to spray fuel, which leaves a mark on the plug. The position of the mark is then checked to determine whether the fuel injector or the injection insert should be rotated to align the insert passage with the fuel injector injection orifice. However, this technique can be difficult to assemble, can contaminate the fuel injector and / or the injection insert, and can be time-consuming. Due to the limitations of these methods, none of these techniques are suitable for mass production. A system or method different from those currently available may be required. Summary of the Invention

[0007] In one embodiment, a method is provided comprising inserting an optical sensor device into a passageway of a body located between a fuel injector and a combustion chamber of an engine cylinder. The body is shaped to transfer fuel ejected from an injection port in the fuel injector to the combustion chamber of the engine cylinder. The method further comprises determining, based on an output from the optical sensor device, whether the passageway of the body is aligned with the injection port of the fuel injector, and, in response to determining that the passageway of the body is misaligned with the injection port of the fuel injector, changing the position of one or more of the body or the fuel injector.

[0008] In one embodiment, the alignment system includes an optical sensor device that can be inserted into a passageway in a body located between a fuel injector and a combustion chamber of an engine cylinder. The body is shaped to deliver fuel ejected from an injection orifice in the fuel injector to the combustion chamber of the engine cylinder. The system also includes a controller that can examine the output of the optical sensor device and determine, based on the output from the optical sensor device, whether the passageway of the body is aligned with the injection orifice of the fuel injector. The controller can change the position of one or more of the body and / or the fuel injector in response to determining that the passageway of the body is misaligned with the injection orifice of the fuel injector. Attached Figure Description

[0009] The subject matter of this invention can be understood by referring to the following description of non-limiting embodiments, in which:

[0010] Figure 1 An example of an injection insert that connects to the cylinder head of an engine cylinder is shown;

[0011] Figure 2 Examples of optical sensor devices are shown;

[0012] Figure 3 Show Figure 1 The sensor device shown in the figure Figure 1 Insertion in the injection insert shown in the figure;

[0013] Figure 4 Cross-sectional views of the cylinder head, injection inserts, and fuel injector are shown.

[0014] Figure 5 An example of an automated inspection system is illustrated schematically.

[0015] Figure 6 This shows the output of the sensor device when the injection opening of the fuel injector and the internal passage of the injection insert are not aligned with each other;

[0016] Figure 7 This shows the output of the sensor device when the injection opening of the fuel injector and the internal passage of the injection insert are aligned with each other;

[0017] Figure 8 An example of a sliding-fit alignment tool attached to a sensor device is shown;

[0018] Figure 9 A flowchart illustrating an example of a method for aligning the internal passage of an injection insert with the injection orifice of a fuel injector;

[0019] Figure 10 A cross-sectional view is shown of another example of an alignment insert device and a fuel injector. Detailed Implementation

[0020] The subject matter described herein relates to systems and methods for aligning liquid flow with and receiving conduits, passages, orifices, or openings. In one embodiment, the subject matter relates to a combustion device fuel supply system where the nozzle of a fuel injector needs to be aligned with a fuel passage that receives fuel injection and entrained air from the nozzle. In one instance, the subject matter described herein relates to a combustion device (e.g., a ducted fuel injector, an injection insert that alters the original trajectory of fuel injection, etc.) where a fuel passage or other component needs to be positioned or aligned near the fuel injector for operation.

[0021] Regarding fuel, in one embodiment the fuel may be a single fuel type, and in other embodiments the fuel may be a mixture or combination of multiple different fuels. In one example of a fuel mixture, the first fuel may be liquid and the second fuel may be gaseous. Suitable liquid fuels may be diesel (conventional diesel, biodiesel, hydrogenated derived renewable diesel (HDRD) and the like), gasoline, kerosene, dimethyl ether (DME), ethanol, and the like. Suitable gaseous fuels may be natural gas (methane) or short-chain hydrocarbons, hydrogen, ammonia, and the like. In one embodiment, the fuel may contain stored energy as used herein.

[0022] In one embodiment, an alignment and inspection system is provided. The system includes an optical sensor device that can be inserted into a fuel or gas (e.g., air) passage of a body located between a fuel injector and a combustion chamber of an engine cylinder, the body being configured to deliver fuel ejected from an injection orifice in the fuel injector to the combustion chamber of the engine cylinder. A controller can inspect the output of the optical sensor device and can determine, based on the output from the optical sensor device, whether the fuel passage of the body is aligned with the injection orifice of the fuel injector. The controller can change the position of one or more of the body or the fuel injector in response to determining that the fuel passage of the body is misaligned with the injection orifice of the fuel injector.

[0023] In another embodiment, a method is provided. The method may include inserting an optical sensor device into a passageway of a body located between a fuel injector and a combustion chamber of an engine cylinder, the body being configured to transfer fuel ejected from an injection port in the fuel injector to the combustion chamber of the engine cylinder. Alignment of the fuel passageway of the body with the injection port of the fuel injector can be determined based on output from the optical sensor device. Furthermore, the position of one or more of the body or the fuel injector can be changed in response to determining that the fuel passageway of the body is misaligned with the injection port of the fuel injector.

[0024] Figure 1 An example of an injection insert or injection insert device 100 connected to the cylinder head 102 of an engine cylinder is shown. The injection insert can be positioned at ( Figure 4 Above the fuel injector (as shown), fuel injected by the fuel injector is received into the injection insert, mixed with air or other gases in the injection insert, and the fuel-air mixture exits the injection insert via outlet 104. During operation, the injection insert delivers the fuel-air mixture to the combustion chamber of the engine cylinder.

[0025] Figure 2 An example of an optical sensor device 200 is shown. The sensor device can be used to align and / or verify the alignment of the injection insert with the fuel injector, as described herein. In the illustrated example, the sensor device is a pipe mirror with a thin flexible tube 202, an eyepiece or camera connector 204 at one end of the sensor device, and a lens 206 at the other end of the sensor device (and at the end of the flexible tube). A cable light source 208 may include an optical fiber cable to deliver direct light along the length of the flexible tube. A user of the sensor device can look through the eyepiece to view the field of view of the lens. Alternatively, a camera may be coupled to a camera connector to generate an image or video of the lens's field of view. Optionally, a camera may be used to record images and / or video of this field of view of the lens.

[0026] Figure 3 The insertion of the sensor device into the injection insert is shown, and Figure 4 A cross-sectional view of the cylinder head, injection insert, and fuel injector 400 is shown. The injection insert may include several internal fuel passages 402, or may actually include pipes located at different positions around the central axis 404 of the injection insert. Each of the internal passages extends in the injection insert from the inlet opening 406 of the injection insert to a corresponding outlet. The lens or camera tip of a sensor device may be inserted into one of the outlets of the injection insert (e.g., ...). Figure 3 (As shown in the diagram) and pointing towards the injection hole 408 in the distal tip 410 of the fuel injector. The fuel injector may include several injection holes. Fuel 412 is ejected from the injection holes from the tip of the fuel injector. Figure 3 As shown and in conjunction with the following text Figure 10 The description suggests that markings 1008 and 1010 can be added or manufactured on the injection insert and cylinder head to help align the injection insert with the fuel injector.

[0027] An operator or automated inspection system examines the interior of the passageway in the injection insert to determine if the inlet opening and internal passageway of the injection insert are aligned with the injection orifice. In one embodiment, a sensor device may be manually used by an operator to visually inspect the interior of the passageway. In another embodiment, an automated inspection system may be used to automatically inspect the interior of the passageway. Figure 5 An example of an automated inspection system 900, also known as a conduit or passage alignment system, is schematically shown. The inspection system may include a conveyor 902 on which one or more cylinder heads, along with injection inserts on the cylinder heads, are mounted. The inspection system may also include a controller 904 having one or more flexible tubes with the sensor array described above. The controller may include hardware circuitry including and / or connected to one or more processors (e.g., one or more integrated circuits, field-programmable gate arrays, etc.) and a camera coupled to the flexible tube (e.g., an optical fiber), which inspects the field of view of a lens at the end of the flexible tube. The controller may inspect the image or video output by the camera to determine whether the internal passage of the injection insert is aligned with the injection orifice of the fuel injector. The conveyor may move one or more of the inserts within the flexible tube of the controller, allowing the controller to inspect one or more inserts simultaneously. Optionally, the inspection system may include a robotic arm 908 capable of gripping and repositioning the injection inserts or replacing those injection inserts that are misaligned with the injection orifice of the fuel injector. Alternatively, the robotic arm can grip and move a fuel injector whose injection port is misaligned with the internal passage of the injection insert on the opposite side of the cylinder head. Alternatively, the robotic arm can place the insert in the cylinder head while simultaneously aligning the insert with the injector.

[0028] If necessary, the focal length or focus of the sensor device can be checked and modified before inserting the lens end of the sensor device into the outlet of the internal passage in the injection insert. If the center of the injection orifice and the center of the internal passage are not aligned with each other, the fuel injector and / or injection insert can be moved relative to each other. For example, the fuel injector can be rotated, the injection insert can be rotated, both the fuel injector and the injection insert can be rotated (e.g., in opposite directions), the fuel injector and / or injection insert can be moved axially relative to each other, the torque or placement force applied to the injector, insert, or other components can be increased or decreased, gaskets can be inserted (or removed), the thickness of sealing gaskets can be adjusted, or similar operations can be performed. Optionally, without changing the position of the fuel injector and / or injection insert, different injection inserts can be used. For example, different fuel inserts can have internal passages at different axial positions in the insert (e.g., different positions between the top side of the insert facing away from the combustion chamber and the opposite bottom side of the insert facing the combustion chamber). If the first fuel insert does not have an internal passage aligned with the injection orifice of the fuel injector, the first fuel insert can be removed and replaced with a different second fuel insert having an internal passage at a different axial distance from the fuel injector. The alignment of the internal passage and the injection orifice can be checked, and if misalignment is found, the second fuel insert can be replaced with another injection insert having an internal passage at a different location. This process can continue until an injection insert with an internal passage aligned with the injection orifice is found.

[0029] As another example, several different fuel inserts with different sizes and / or passages in different locations can be grouped, compartmented, or otherwise organized into different sets or groups, such that fuel inserts of similar or identical sizes and / or inserts with passages in the same location are in the same set or group. Measurements can be made of the cylinder head and / or the fuel injector (e.g., a measurement of how far the distal tip of the fuel injector protrudes outward from the surface of the cylinder head). Different groups or sets of inserts can be associated with different measurements (or ranges of measurements). An operator or automated inspection system can then select a fuel insert from the set associated with the measurements and attach it to the cylinder head. This fuel insert can then be inspected to determine if it is aligned with the fuel injector, as described herein. If the passage in the fuel insert is not aligned with the fuel injector, the fuel insert can be repositioned and / or replaced with another fuel insert until the fuel passage of the fuel insert is aligned with the fuel injector.

[0030] A seal can be positioned between the fuel insert and the cylinder head. For example, a sealing gasket, liner, or shim can be placed between the fuel insert and the cylinder head and can be partially compressed between the fuel insert and the cylinder head. The fuel insert can be partially screwed onto the threads of the injector sleeve 1000 by means of a seal between the fuel insert and the cylinder head (e.g., Figure 10 (As shown in the diagram and described below), but it is not necessary to fully screw the fuel insert onto the threads. If necessary, the focal length or focus of the sensor device can be checked and modified before inserting the lens end of the sensor device into the outlet of the internal passage in the injection insert. Once the passage of the fuel insert is aligned, the fuel insert can be twisted or screwed onto the injector sleeve to compress the seal between the fuel insert and the cylinder head (while also securing the fuel insert to the cylinder head).

[0031] A light source can be used to illuminate the injection orifice of the fuel injector. This can be a direct light source (e.g., a cable light source of the sensor device), which directs light along the length of the flexible tube to illuminate the interior of the internal passage. Optionally, a separate or independent light source can be used, such as another light source that is separately controlled and provides additional direct light into the internal passage. For example, a laser source, LED, or other lamp can be inserted into or oriented into the injection insert such that the light is directed toward the injection orifice of the fuel injector. The light source can be an indirect light source that directs light in a direction other than along the length of the flexible tube. For example, the light source can be inserted into a passage of the injection insert that is different from the passage into which the lens or camera end of the sensor device is inserted. This passage can be an air or gas passage, or it can be another fuel passage. Direct or indirect light sources can emit polarized light or another type of light. Using direct and / or indirect light sources can improve the quality of the output from the sensor device (e.g., by reducing glare), thereby making the injection orifice easier for the operator to see. In addition, the use of polarized light sources and polarizing filters can reduce glare from surrounding metal to provide a clearer image.

[0032] Instead of imaging one of the injection orifices at the nozzle tip of the fuel injector, a mark can be added to the tip of the fuel injector, such as a machining feature or a brush mark. This mark can serve as a reference mark for alignment purposes. This mark will act as a reference mark for the reference injector orifice. The mark can be imaged through one of the internal passages of the injection insert, or another access passage can be created or identified for alignment marking. This mark can also help reduce glare from direct or indirect light sources.

[0033] The alignment mark can be located at a known rotation angle from the fuel injector orifice, allowing the mark to be positioned by the inspection system through the internal passage of the injection insert. If the fuel injector and injection insert are misaligned, the inspection system can then index the fuel injector and / or injection insert by an appropriate amount to align the fuel injection orifice with the internal passage.

[0034] Figure 6 This illustrates the sensor device output 504 when the fuel injector's injection orifice and the internal passage of the injection insert are misaligned. The sensor device output can be video or image of the sensor device's lens or camera's field of view. The fuel injector's injection orifice is represented in the sensor device output as a darkened area or pit 502. A bright circle 500 indicates the position of the injection insert's internal passage. This can be checked by the operator or automation system. Figure 6 The sensor device shown outputs and determines that the fuel injector's injection orifice is misaligned with the internal passage because the injection orifice is not located within the bright circle of the internal passage. The operator or inspection system may subsequently move the fuel injector and / or injection insert, or replace the injection insert, so that the fuel injector's injection opening and the injection insert's internal passage are aligned.

[0035] Figure 7 This diagram illustrates the sensor device output when the fuel injector's injection opening and the internal passage of the injection insert are aligned with each other. As shown, the fuel injector's injection opening is represented by a gray or darker circle 600 within the illuminated circle 500 of the internal passage. This indicates alignment between the injection opening and the internal passage of the injection insert. Operators and / or inspection systems can then check this alignment. Figure 6 The sensor device output shown in the diagram determines that the fuel injector's injection orifice is aligned with the internal passage. An operator or inspection system can then remove the sensor device from the injection insert.

[0036] Figure 8 An example of a sliding-fit alignment tool 700 attached to a sensor device is shown. The sliding-fit alignment tool may represent a sleeve or sheath disposed around a portion of a flexible tube of the sensor device. The sliding-fit alignment tool can slide onto the lens or camera end of the sensor device, wherein the lens or camera end protrudes beyond the outer or distal end 702 of the sliding-fit alignment tool. The sliding-fit alignment tool can be sized to fit snugly within the internal passage of the injection insert.

[0037] The flexible tube of the sensor device can be smaller than the inner diameter 704 of the internal passage of the injection insert. For example, the outer diameter 708 of the sensor device at or near the end of the lens or camera can be less than one millimeter, while the inner diameter of the internal passage can be, for example, 2 millimeters.

[0038] The outer diameter 706 of the sliding-fit alignment tool can be smaller than the inner diameter of the internal passage of the injection insert, but larger than the outer diameter of the sensor device at the lens or camera end of the sensor device. For example, the outer diameter of the sliding-fit alignment tool can be two millimeters, three millimeters, or a similar size. The sliding-fit alignment tool can fill many or all of the space between the tube of the sensor device and the inner diameter of the internal passage of the injection insert. This helps to center the lens or camera end of the sensor device within the internal passage of the injection insert, allowing the lens or camera end to be aligned and oriented toward the entrance of the internal passage.

[0039] The alignment tool may include a depth adjuster device 710 along the outer surface of the sleeve or sheath. This depth adjuster device may include an O-ring, a nylon disc, or other non-coilable body attached to the outer surface of the sleeve or sheath. The depth adjuster device limits how far the exposed lens end of the flexible tube of the sensor device protrudes into the internal passage of the injection device. The depth adjuster device may be larger than the outlet of the internal passage of the injection device. The depth adjuster device may be positioned at a distance from the distal end of the sheath or sleeve, causing the lens end of the sensor device to be at the same depth or distance within the internal passage. This depth or distance may be set as the focal point or focal length of the lens, for example, causing the injection orifice to be in a focal-aligned position when the lens end of the flexible tube is inserted into the internal passage. The use of the sleeve or sheath and the depth adjuster device allows the sensor device to be used more quickly to inspect multiple injection inserts because the lens end of the sensor device will be repeatedly inserted to the same depth and aligned along the length of the internal passage of the injection insert.

[0040] Figure 9A flowchart illustrates an example of a method 800 for aligning the internal passage of an injection insert with the injection orifice of a fuel injector. The method includes inserting an optical sensor device into the outlet of the internal passage of the injection insert in step 802. Optionally, a sliding-fit alignment tool, which may include a depth adjuster device, may be positioned above a portion of the sensor device at the lens or camera end before inserting the lens or camera end into the outlet. In step 804, the interior of the internal passage of the injection insert is visually inspected. The operator may manually inspect the internal passage by looking through the eyepiece of the sensor device or by viewing the camera output on a screen, or the inspection system may automatically inspect the internal passage. In step 806, a visual inspection is used to determine whether the injection orifice of the fuel injector is aligned with the internal passage of the injection insert. If the injection orifice and the internal passage are aligned, the sensor device can be removed from the injection insert when the fuel injector and injection insert are determined to be correctly aligned (in step 808). Therefore, the injection insert and fuel injector are ready for use in the engine. If the injection orifice and the internal passage are not aligned with each other, then the injection insert and / or fuel injector can be moved (in step 810), as described above, and the flow of the method can be reversed toward 804 to check the alignment of the injection orifice and the internal passage, as described above.

[0041] In one embodiment, the alignment of the nozzle orifice and the injection insert orifice is evaluated for alignment, such that the centerline of the nozzle exit and the injection insert inlet is the evaluation metric. In another embodiment, the fuel injection cone from the nozzle orifice is evaluated relative to the outer diameter of the injection insert inlet. The size of the fuel injection cone can be estimated, modeled, or measured. The alignment process can then adjust various parameters of the system that are available for adjustment. For example, the cross-sectional configuration of the fuel injection cone can vary with the distance the fuel travels from the nozzle (with consistent pressure and fuel characteristics). Therefore, in the case where the fuel cone impacts the injection insert outside the target injection insert inlet, the distance between the nozzle exit and the injection insert inlet can be adjusted to achieve the desired state. The desired state may be, for example, the case where the injected fuel cone is fully inside the inlet. Naturally, a narrow cone (e.g., a flow) will be more easily accommodated within the inlet than an extremely wide extension; however, the narrower the cone, the less likely fuel / oxidizer mixing may occur. Therefore, in one embodiment, the system may attempt to maximize the cone width while maintaining the desired alignment.

[0042] In one embodiment, the system can adjust the cone width itself, for example, by adjusting the pressure of the fuel flow injected through the nozzle by the fuel control system. The system can, for example, set a maximum pressure injection threshold based on calculations that additional pressure would produce a cone that is too wide to fully flow into the inlet. In other embodiments, other factors can be considered. For example, if fuel characteristics (e.g., viscosity) are known, the system can calculate the injection pattern. And, given the determination that the viscosity produces an undesirably wide (relative to the inlet) cone, the system can compensate by adjusting other parameters to maintain proper alignment of the fuel injection cone with the inlet. These other parameters may include pulsed fuel injection, adjusted fuel pressure, and adjusted fuel injection timing.

[0043] As the injection insert wears over time, the choice of fuel injector nozzle can compensate for the change. In cases where the fuel passage of the injection insert is narrow (e.g., due to buildup on the inner surface of the inlet), an injector nozzle can be selected that injects a narrower fuel cone and thus maintains the fuel injection cone within the inlet passage. Conversely, in cases where the fuel passage of the injection insert widens (e.g., due to abrasion or loss of material on the sidewalls of the fuel passage), a nozzle that produces the same cone size or even a larger cone size can be selected (and thus increase the mixing potential and efficiency of the unworn system).

[0044] Figure 10 A cross-sectional view is shown of another example of an alignment insert device and a fuel injector. As shown in the figure, the injection insert is connected to an injector sleeve 1000. The sleeve may optionally be screwed onto or into the insert device and abuts against a shoulder on the cylinder head. The sleeve supports the fuel injector and holds the insert device in place relative to the fuel injector. As shown, the sleeve may include an external thread 1002 that mates with an internal thread 1004 disposed along the inner surface 1006 of the insert device. These external and internal threads may engage with each other to secure the insert device to the sleeve and, consequently, to the cylinder head.

[0045] During the installation of the insert device, the injector can be installed in the cylinder head, and the internal thread of the insert device can engage the external thread of the sleeve (e.g., screw it onto it). The insert device can be screwed onto the sleeve using a manual level torque, such as a finger-tightening level torque, which an average person with average strength can generate manually without any additional tools. Furthermore, an injector clamp can be installed on the injector, and a clamping bolt can be installed to a finger-tightening level torque. The position of the insert device can be adjusted as described herein to ensure that the fuel passage of the insert device body is aligned with the injection port of the fuel injector.

[0046] Once this alignment is achieved, it can be aligned with mark 1010 on the cylinder head. Figure 3 (As shown in the image) Mark 1008 is made on the main body of the insert device. Figure 3 (As shown in the diagram), or markings may be made on both the body of the insert device and the cylinder head to indicate the rotational position of the insert device aligning the fuel passage of the insert device with the injection port of the fuel injector. For example, an ink line may be drawn on the insert device at a position collinear with a marking already on the cylinder head, an ink line may be drawn on the cylinder head at a position collinear with a marking already on the insert body, or an ink line may be drawn on the cylinder head and from the insert device to the cylinder head (e.g., a line extending across the interface between the insert device and the cylinder head). Alternatively, another mark or multiple marks may be made on the insert device and / or the cylinder head to at least temporarily record the rotational position of the insert device aligned with the fuel injector, as described above. The marks may be added or generated using ink or another material, or optionally, the marks may be cut into the injection insert and / or the cylinder head. For example, one or more of the marks may be perforated, recessed, or etched in the injection insert and / or the cylinder head using a sharp tool. Alternatively, markings can be made in the injection insert and / or cylinder head, for example, by additive manufacturing, casting, molding, etc., of the body of the injection insert and / or cylinder head to include elongated grooves or recesses as markings.

[0047] The fuel injector can then be removed from the cylinder head (e.g., in a direction away from the insert device, or...). Figure 10 (Vertically upwards). The sleeve can then be twisted or screwed onto the insert assembly with a force greater than the manual force described above (and optionally, onto the cylinder head if the cylinder head contains internal threads that mate with the external threads of the sleeve). For example, a long, thin tool and / or power tool, such as a ratchet, wrench, or similar object, can be used to apply torque to the sleeve to increase the force required to rotate the sleeve relative to the cylinder head and / or the insert body (greater than the force that can be applied manually without tools). During this twisting of the sleeve, the insert body can remain aligned with the fuel injector by keeping the markings on the insert assembly aligned (e.g., collinear) with the markings on the cylinder head. The fuel injector can then be installed into the cylinder head, with the fuel injector's injection orifice aligned with the injection insert, as described above.

[0048] While the subject matter described herein specifically addresses the alignment between a fuel injector and an injection insert, the subject matter can also be applied to ducted fuel injection and any number of other combustion enhancement techniques in which the apparatus requires precise positioning relative to the fuel injection nozzle. Furthermore, one embodiment can be used to align the passage of the first body with the passage or opening of the second body.

[0049] In one embodiment, a method is provided comprising inserting an optical sensor device into a fuel passage of a body located between a fuel injector and a combustion chamber of an engine cylinder. The body is shaped to transfer fuel ejected from an injection port in the fuel injector to the combustion chamber of the engine cylinder. The method further comprises determining, based on output from the optical sensor device, whether the fuel passage of the body is aligned with the injection port of the fuel injector, and, in response to determining that the fuel passage of the body is misaligned with the injection port of the fuel injector, changing the position of one or more of the body or the fuel injector.

[0050] The body may be an injection insert that mixes fuel and air from the fuel injector as fuel is transferred through the injection insert. The body may be a fuel conduit. Changing the position of the body and / or the fuel injector may include one or more of the following operations: rotating the body relative to the fuel injector, and / or rotating the fuel injector relative to the body.

[0051] Changing the position of one or more of the body and / or fuel injector may include one or more of the following operations: axially moving the body relative to the fuel injector, and / or axially moving the fuel injector relative to the body. The method may also include placing a sliding-fit alignment tool above the optical sensor device to reduce the gap between the inner diameter of the internal passage of the body and the outer diameter of the optical sensor device. The sliding-fit alignment tool may be placed above the optical sensor device such that the lens at the distal end of the optical sensor device protrudes beyond one end of the sliding-fit alignment tool. The method may also include placing a depth adjuster device around the optical sensor device to position the lens at the distal end of the optical sensor device so that it is focused on the injection orifice of the fuel injector.

[0052] Determining whether the fuel passage of the subject is aligned with the injection orifice of the fuel injector may include determining whether the fuel passage and the injection orifice are coaxial with each other. The method may also include removing an optical sensor device from the fuel passage of the subject in response to determining that the fuel passage of the subject is aligned with the injection orifice of the fuel injector. The method may include inserting a light source into the subject to improve image quality. The light source may be inserted into the fuel passage. Alternatively, the light source may be inserted into a passage of the subject other than the fuel passage. The light source may be positioned to transmit light via an optical path coaxial with an imaging path extending along the length of the fuel passage. The light source may generate polarized light, and the method may also include using one or more polarizing filters to improve image quality.

[0053] The method may also include adding a mark or feature to the injector nozzle at a marked location at a specified distance from the orifice position of the fuel injector. Determining whether the fuel passage of the body is aligned with the fuel injector's orifice may include visually inspecting the fuel injector through the fuel passage to find a visible mark or feature.

[0054] Changing the position of one or more of the body and / or fuel injector may involve rotating or axially distributing one or more of the body or fuel injector by a specified distance, which is associated with a mark position and a bore position. The automated inspection system may perform one or more of the following: inserting an optical sensor device, determining fuel passage alignment, and / or changing the position of one or more of the body or fuel injector. Inserting the optical sensor device and determining fuel passage alignment may include simultaneously inserting multiple optical sensor devices into multiple fuel passages in multiple bodies and determining whether one or more fuel passages are aligned with their corresponding fuel injectors. The optical sensor device may be a pipe mirror.

[0055] In one embodiment, the alignment system includes an optical sensor device that can be inserted into a fuel passage in a body located between a fuel injector and a combustion chamber of an engine cylinder. The body is shaped to transfer fuel ejected from an injection orifice in the fuel injector to the combustion chamber of the engine cylinder. The system also includes a controller that can examine the output of the optical sensor device and determine, based on the output, whether the fuel passage of the body is aligned with the injection orifice of the fuel injector. The controller can change the position of the body or one or more of the fuel injectors in response to determining that the fuel passage of the body is misaligned with the injection orifice of the fuel injector.

[0056] The body may be an injection insert that mixes fuel and air from the fuel injector as fuel is transferred through the injection insert. The body may be a pipe. The controller may change the position of the body or the fuel injector by rotating the body relative to the fuel injector, or rotating the fuel injector relative to the body, using one or more of the following operations. The controller may change the position of the body and / or the fuel injector by axially moving the body relative to the fuel injector, and / or axially moving the fuel injector relative to the body, using one or more of the following operations. Axial movement may be accomplished using shims, crushable gaskets or washers, sleeves of different sizes, or inserts of different sizes, etc.

[0057] The controller can determine whether the fuel passage of the main body is aligned with the injection orifice of the fuel injector by determining whether the fuel passage and the injection orifice are coaxial with each other. The controller can remove the optical sensor device from the fuel passage of the main body in response to determining that the fuel passage of the main body is aligned with the injection orifice of the fuel injector. The controller can insert a light source into the main body to improve image quality. The controller can insert a light source into the fuel passage.

[0058] The controller can insert a light source into a passageway of the subject other than the fuel passageway. The controller can insert the light source into the subject such that light from the light source is transmitted via an optical path coaxial with the imaging path extending along the length of the fuel passageway. The controller can use one or more polarizing filters to improve image quality. The controller can determine whether the fuel passageway of the subject is aligned with the injection orifice of the fuel injector by visually inspecting the fuel injector through the fuel passageway to find visible markings or features on the fuel injector.

[0059] The controller can change the position of one or more of the body and / or fuel injectors by rotating or axially by a specified distance relative to the position of the markings and the position of the injection orifice. The controller can simultaneously insert multiple optical sensor devices into multiple fuel passages in multiple bodies and is configured to determine whether one or more fuel passages are aligned with their corresponding fuel injectors. The optical sensor devices may be duct mirrors.

[0060] As used herein, the terms “processor” and “computer,” as well as related terms such as “processing device,” “computing device,” and “controller,” are not limited to those integrated circuits referred to as computers in this art, but also refer to microcontrollers, microcomputers, programmable logic controllers (PLCs), field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), and other programmable circuits. Suitable memory may comprise, for example, a computer-readable medium. A computer-readable medium may be, for example, random access memory (RAM), a computer-readable non-volatile medium, such as flash memory. The term “non-transitory computer-readable medium” refers to a tangible computer-based device implemented for short-term and long-term information storage, such as computer-readable instructions, data structures, program modules and submodules, or other data in any device. Therefore, the methods described herein can be encoded as executable instructions implemented within a tangible non-transitory computer-readable medium that includes, but is not limited to, storage devices and / or memory devices. Such instructions, when executed by a processor, cause the processor to perform at least a portion of the methods described herein. Therefore, the term includes tangible computer-readable media, including but not limited to non-transitory computer storage devices, including but not limited to volatile and non-volatile media, and removable and non-removable media, such as firmware, physical and virtual storage devices, CD-ROMs, DVDs, and other digital sources, such as networks or the Internet.

[0061] Unless the context explicitly indicates otherwise, the singular forms “a” and “the” include plural references. “Optional” or “optionally” means that the event or situation subsequently described may or may not occur, and this specification may include instances of events occurring and instances of events not occurring. As used herein throughout the specification and claims, approximate language may be used to modify any quantitative representation that may allow variation without causing a change in the fundamental function it may involve. Thus, a value modified by one or more terms such as “about,” “substantially,” and “approximate” may not be limited to the specified precise value. In at least some cases, approximate language may correspond to the precision of the instrument used to measure said value. Scope limitations herein and throughout the specification and claims may be combined and / or interchanged, and unless the context or language otherwise indicates, such scopes may be identified and include all subscopes included therein.

[0062] This written description uses examples to disclose embodiments containing the best mode and to enable those skilled in the art to practice the said embodiments, including making and using any apparatus or system and performing any incorporated methods. The claims define the patentable scope of this disclosure and include other examples known to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements identical to the literal language of the appended claims, or if they have equivalent structural elements that are not substantially different from the literal language of the claims.

Claims

1. An alignment method, comprising: An optical sensor device is inserted into a passageway in a body located between a fuel injector and the combustion chamber of an engine cylinder, the body being configured to transfer fuel ejected from an injection port in the fuel injector to the combustion chamber of the engine cylinder; Glare is reduced by using a polarized light source and / or a polarizing filter for the optical sensor device, thereby improving the quality of the output from the sensor device. The output from the improved optical sensor device determines whether the passage of the body is aligned with the injection port of the fuel injector; In response to determining that the passage of the body is misaligned with the injection orifice of the fuel injector, the position of one or more of the body or the fuel injector is changed; as well as In response to determining that the passage of the body is aligned with the injection port of the fuel injector, the optical sensor device is removed from the passage of the body.

2. The method of claim 1, wherein the body is an injection insert that mixes the fuel from the fuel injector with air as the fuel is transferred through the injection insert.

3. The method according to claim 1, wherein the main body is a fuel pipeline.

4. The method of claim 1, wherein changing the position of one or more of the body or the fuel injector comprises one or more of the following operations: rotating the body relative to the fuel injector, or rotating the fuel injector relative to the body.

5. The method of claim 1, wherein changing the position of one or more of the body or the fuel injector comprises one or more of the following operations: axially moving the body relative to the fuel injector, or axially moving the fuel injector relative to the body.

6. The method of claim 5, wherein changing the position of one or more of the body or the fuel injector comprises changing one or more of the gasket, liner, different injection insert or different injector sleeve to provide axial movement of the body.

7. The method of claim 1, further comprising placing a sliding alignment tool above the optical sensor device to reduce the gap between the inner diameter of the passage of the body and the outer diameter of the optical sensor device, wherein the sliding alignment tool is placed above the optical sensor device such that a lens at the distal end of the optical sensor device protrudes beyond one end of the sliding alignment tool.

8. The method of claim 1, further comprising placing a depth adjuster device around the optical sensor device to position a lens at the distal end of the optical sensor device so that it is focused on the injection orifice of the fuel injector.

9. The method of claim 1, wherein determining whether the passage of the body is aligned with the injection orifice of the fuel injector comprises determining whether the passage and the injection orifice are coaxial with each other.

10. An alignment system, comprising: An optical sensor device is configured to be inserted into a passageway in a body located between a fuel injector and a combustion chamber of an engine cylinder, the body being configured to transfer fuel ejected from an injection port in the fuel injector to the combustion chamber of the engine cylinder, wherein glare is reduced by using a polarizing light source and / or a polarizing filter for the optical sensor device, thereby improving the quality of the output from the sensor device; and A controller configured to examine the output of the optical sensor device whose quality is improved and to determine, based on the output of the optical sensor device, whether the passage of the body is aligned with the injection orifice of the fuel injector, the controller being configured to change the position of one or more of the body or the fuel injector in response to determining that the passage of the body is misaligned with the injection orifice of the fuel injector, wherein the controller is configured to remove the optical sensor device from the passage of the body in response to determining that the passage of the body is aligned with the injection orifice of the fuel injector.

11. The system of claim 10, wherein the body is an injection insert that mixes the fuel from the fuel injector with air as the fuel is transferred through the injection insert.

12. The system of claim 10, wherein the controller is configured to change the position of the body or the fuel injector by one or more of the following operations: rotating the body relative to the fuel injector, or rotating the fuel injector relative to the body.

13. The system of claim 10, wherein the controller is configured to change the position of the body or the fuel injector by one or more of the following operations: axially moving the body relative to the fuel injector, or axially moving the fuel injector relative to the body.

14. The system of claim 10, wherein the controller is configured to determine whether the passage of the body is aligned with the injection orifice of the fuel injector by determining whether the passage and the injection orifice are coaxial with each other.

15. The system of claim 10, wherein the controller is configured to insert a light source into the body to improve imaging quality.

16. The system of claim 10, wherein the controller is configured to simultaneously insert a plurality of the optical sensor devices into a plurality of the passages in a plurality of the bodies, and is configured to determine whether one or more of the passages are aligned with a corresponding fuel injector.

17. The system of claim 10, wherein the optical sensor device is a pipe mirror.

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