Ejector maintenance tool

Abstract

A fuel injector tool includes a first adjustment plate, a first stator plate connected or attached to a second stator plate, a second adjustment plate, and a third stator plate. The first adjusting plate is operably connected to the second adjusting plate through a plurality of adjusting rods. The first stator plate is operably connected to the third stator plate by a plurality of stator rods. The plurality of adjustment rods extend through the first stator plate and assist the plurality of stator rods in maintaining an orientation of the first stator plate relative to the first adjustment plate. The plurality of adjustment rods and the plurality of stator rods are positioned to enable a worker to use a tool on the injector and have a sufficient amount of clearance distance for the tool to access the injector. The stroke length of the ejector is adjusted through the upper adjusting nut and the lower adjusting nut.

Description

Technical Field

[0001] This application generally relates to an injector repair tool, and more particularly, to an injector repair tool for disassembling, reassembling, and installing a fuel injector for an internal combustion engine. Background Art

[0002] The performance of a fuel injector affects the performance of an internal combustion engine. Thus, inspecting the fuel injector and replacing a damaged fuel injector can greatly improve the performance of the internal combustion engine. To inspect the fuel injector, the fuel injector is typically removed and disassembled from the engine. The removal of the fuel injector can be time-consuming and difficult. Replacing a damaged fuel injector with a new fuel injector is expensive. In addition, after the fuel injector is out of warranty, the fuel injector typically fails, which also increases the cost of replacing any damaged fuel injector.

[0003] Accordingly, a further contribution is needed in this technical field to improve the technology for removing and disassembling a fuel injector from an engine. Summary of the Invention

[0004] One embodiment is a fuel injector tool having a compact size. The fuel injector tool includes a first adjustment plate, a first stator plate connected or attached to a second stator plate, a second adjustment plate, and a third stator plate. The first adjustment plate is operably connected to the second adjustment plate by a plurality of adjustment rods. The first stator plate is operably connected to the third stator plate by a plurality of stator rods. The plurality of adjustment rods extend through the first stator plate and assist the plurality of stator rods in maintaining the position or orientation of the first stator plate relative to the first adjustment plate. The plurality of adjustment rods and the plurality of stator rods are positioned such that a worker can use the tool on the fuel injector and have a sufficient amount of clearance distance for the tool to access the fuel injector. The third stator plate includes a plurality of mounting holes to enable the fuel injector tool to be mounted to a work surface.

[0005] The fuel injector tool can be used to disassemble and assemble a fuel injector in a single assembly. The fuel injector tool does not require several small additional fixtures to achieve partial disassembly and installation of the fuel injector. The disassembly and assembly of the fuel injector in the fuel injector tool enables inspection, repair, cleaning, replacement, and adjustment of the upstroke of fuel injection as needed. The fuel injector tool can be used to disassemble the fuel injector 102 into sub-components. The fuel injector tool can be used to assemble the sub-components of the fuel injector into a complete fuel injector. The fuel injector tool can be used to perform a coarse or large adjustment and / or a fine or small adjustment of the upstroke of the fuel injector.

[0006] The fuel injector tool uses the bolt thread engagement principle of a push and / or pull disassembly tool to disassemble or install the injector solenoid valve of the fuel injector. The fuel injector tool adopts a main bolt or lower adjusting nut and an auxiliary bolt or upper adjusting nut passing through the hole, with a screw reinforcement design, and maintains the easy rotation of the lower adjusting nut and the upper adjusting nut without interference from other components. The thread machining distance accuracy of the 2mm main bolt or lower adjusting nut can be a coarse adjustment of the injector upstroke clearance. The thread machining distance accuracy of the 0.8mm upper adjusting nut can be a fine adjustment of the injector upstroke clearance to save work and reduce the error range.

[0007] The fuel injector tool completely disassembles the entire injector for servicing the fuel injector. Other tools only remove the injector from the engine to replace any damaged injectors. A unique aspect of the fuel injector tool is that after the injector is out of warranty, the injector can be serviced without the need to replace the entire injector. The maintenance cost is lower compared to the replacement cost, so the fuel injector tool reduces the maintenance cost of the fuel injector and improves customer satisfaction.

[0008] The present invention content is provided to introduce some concepts further described in the following illustrative embodiments. The present invention content is neither intended to identify the key or essential features of the claimed subject matter nor to be used as an aid in limiting the scope of the claimed subject matter. Additional embodiments, forms, purposes, features, advantages, aspects, and benefits will become apparent from the following description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The concepts described herein are illustrated by way of example and not by way of limitation in the accompanying drawings. For simplicity and clarity of illustration, the elements shown in the figures are not necessarily drawn to scale. Where considered appropriate, reference labels have been repeated in the drawings to indicate corresponding or similar elements.

[0010] Figure 1 is a perspective view of the fuel injector tool of the present disclosure.

[0011] Figure 2 is of the present disclosure Figure 1 side view of the fuel injector tool.

[0012] Figure 3 is of the present disclosure Figure 1 top view of the fuel injector tool.

[0013] Figure 4 is of the present disclosure Figure 1 partial perspective view of the fuel injector tool.

[0014] Figure 5 is of the present disclosure Figure 1Cross-sectional view of a fuel injector tool.

[0015] Figure 6 This disclosure Figure 1 A side view of an exemplary embodiment of a lower adjustment nut of a fuel injector tool.

[0016] Figure 7 yes Figure 5 A top perspective view of the lower adjusting nut.

[0017] Figure 8 yes Figure 5 Top view of the lower adjusting nut.

[0018] Figure 9 yes Figure 5 Cross-sectional view of the lower adjusting nut.

[0019] Figure 10 This disclosure Figure 1 A side view of an exemplary embodiment of an upper adjusting nut of a fuel injector tool.

[0020] Figure 11 yes Figure 10 Cross-sectional view of the upper adjusting nut.

[0021] Figure 12 yes Figure 10 Top view of the upper adjusting nut.

[0022] Figure 13 yes Figure 10 A top perspective view of the upper adjusting nut.

[0023] Figure 14 The use of this disclosure Figure 1 A fuel injector tool is provided to disassemble and / or assemble a fuel injector.

[0024] Figure 15 The use of this disclosure Figure 1 A method of adjusting the upstroke length of a fuel injector using a fuel injector tool. DETAILED DESCRIPTION

[0025] In order to promote an understanding of the principles of the present invention, reference will now be made to the embodiments shown in the drawings and specific language will be used to describe the embodiments. It will be understood, however, that it is not intended to limit the scope of the present invention thereby, and any changes and further modifications of the illustrated embodiments that would normally occur to one skilled in the art to which the present invention relates, as well as any further applications of the principles of the present invention shown herein, are contemplated herein.

[0026] Reference now Figure 1 Turning to this application, Figure 1is a perspective view of a fuel injector tool 100 that allows the installation of a fuel injector 102 for inspection, disassembly, repair, and reassembly and / or upstroke adjustment of the fuel injector 102. In one embodiment, the fuel injector 102 is a fuel injector used in an internal combustion engine. The fuel injector tool 100 includes a first adjustment plate 104, a first stator plate 106 connected or attached to a second stator plate 108, a second adjustment plate 110, and a third stator plate 112. The first adjustment plate 104 is operably connected to the second adjustment plate 110 by a plurality of adjustment rods 118, as described below. The first stator plate 106 is operably connected to the third stator plate 112 by a plurality of stator rods 119, as described below.

[0027] The first adjustment plate 104 includes a slot-shaped opening 122 sized to receive a body nozzle holder 130 of the fuel injector 102, as Figure 1 , Figure 2 and Figure 3 shown. In the illustrated embodiment, the slot-shaped opening 122 includes a retaining tab 126 sized to receive and hold the body nozzle holder 130 of the fuel injector 102. In some embodiments, the body nozzle holder 120 of the fuel injector 102 includes a groove sized to receive the retaining tab 126 therein such that the fuel injector 102 is held or retained in the slot-shaped opening 122. In other embodiments, the slot-shaped opening 122 does not include the retaining tab 126.

[0028] The first adjustment plate 104 includes a plurality of retaining holes 124 positioned around the slot-shaped opening 122. In the illustrated embodiment, three of the plurality of retaining holes 124 are arranged around the slot-shaped opening 122 such that one of the holes 124 is aligned with the longitudinal axis X of the slot-shaped opening 122 and the two remaining holes 124 are aligned with each other. The plurality of retaining holes 124 are sized to receive and retain the plurality of adjustment rods 118. Each of the plurality of retaining holes 124 may include one or more threads to threadedly engage corresponding threaded end portions (not shown) of the plurality of adjustment rods 118. As can be appreciated, the engagement between the threads of the retaining holes 124 and the threaded end portions enables adjustment of the first adjustment plate 104 relative to the plurality of adjustment rods 118, which can assist in positioning the fuel injector 102 within the slot-shaped opening 122 and, in some embodiments, in maintaining the engagement between the tab 126 and the groove on the fuel injector 102. In one form, each of the plurality of retaining holes 124 extends through the thickness of the first adjustment plate 104. In another form, not shown, each of the plurality of retaining holes 124 extends from the bottom surface 132 of the first adjustment plate 104 toward the top surface 134 but does not fully extend through the top surface 134 such that the plurality of retaining holes 124 only extend through a portion of the thickness of the first adjustment plate 104. The plurality of adjustment rods 118 are accessible through the plurality of retaining holes 124 to adjust the position of the first adjustment plate 104 relative to the second adjustment plate 110.

[0029] The second adjustment plate 110 is similar to the first adjustment plate 104 and includes a plurality of retaining holes 142 positioned around an opening 144 sized to receive and retain the lower portion 148 of the fuel injector 102, as Figure 1 , Figure 2 and Figure 4As shown. The sizes of the plurality of retaining holes 142 are set to receive and retain the plurality of adjusting rods 118. When the first adjusting plate 104 and the second adjusting plate 110 are respectively assembled with the plurality of adjusting rods 118, the plurality of retaining holes 142 are positioned to be vertically aligned with the plurality of retaining holes 124 in the first adjusting plate 104. In one embodiment, each of the plurality of retaining holes 142 may include one or more threads to threadedly engage corresponding threaded end portions (not shown) of the plurality of adjusting rods 118. In another embodiment, each of the plurality of retaining holes 142 is configured to receive a lock nut or other locking element to retain the end portions of the plurality of adjusting rods 118. In one form, each of the plurality of retaining holes 142 extends through the thickness of the second adjusting plate 110, that is, from the bottom surface 150 through the top surface 152. In another form (not shown), each of the plurality of retaining holes 142 extends from near the bottom surface 150 of the second adjusting plate 110 through the top surface 152 such that the plurality of retaining holes 142 only extend through a portion of the thickness of the second adjusting plate 110. In one embodiment, the top surface 152 includes angular markings or identifiers 230 to assist and precisely control the adjustment angles of the lower adjusting nut 220 and the upper adjusting nut 222 for the upward stroke adjustment of the fuel injector 102.

[0030] The second adjusting plate 110 includes a plurality of through holes 160, and in the embodiment shown, there are two through holes 160. Each through hole 160 is located outside the plurality of retaining holes 142. The through holes 160 extend through the thickness of the second adjusting plate 110 and respectively extend through the top surface 152 and the bottom surface 150. The size of each through hole 160 is set to receive one of the stator rods 119.

[0031] Now turning to the first stator plate 106 that is connected or attached to the second stator plate 108, as Figure 1 , Figure 2 and Figure 3 shown. The first stator plate 106 includes a plurality of through holes 164 positioned around a slot-shaped opening 166, and the size of the slot-shaped opening is set to receive and retain the middle portion of the fuel injector 102. In one embodiment, the middle portion of the fuel injector 102 includes an injector body 168 and an electrical attachment 170. The slot-shaped opening 166 has an inner surface complementary to the outer surface of the injector body 168 that slides into the slot-shaped opening 166. In the embodiment shown, the slot-shaped opening 166 includes a retaining groove 172 adjacent to the sliding surface 174, and both are configured to receive the outer surface of the injector body 168 in a tight-fitting manner such that the fuel injector 102 is further retained from moving relative to the first stator plate 106. The outer surface of the injector body 168 is configured to be complementary to the inner surface of the slot-shaped opening 166.

[0032] ContinuingFigures 1 to 5 , in the illustrated embodiment, three of the plurality of through-holes 164 are arranged around the slot-shaped opening 166 such that one of the holes 164 is aligned with the longitudinal axis X of the slot-shaped opening 166 and the two remaining holes 164 are aligned with each other. The plurality of through-holes 164 are sized to receive and retain the plurality of adjusting rods 118. As can be appreciated, the engagement between the through-holes 164 and the plurality of adjusting rods 118 can adjust the first adjusting plate 104 relative to the plurality of adjusting rods 118, which can assist in positioning the fuel injector 102 in the slot-shaped opening 122 and, in some embodiments, in maintaining the engagement between the tab 126 and the groove on the fuel injector 102. Each of the plurality of through-holes 164 extends through the thickness of the first stator plate 106.

[0033] The first stator plate 106 includes a plurality of through-holes 176, where in the illustrated embodiment, there are two through-holes 176. Each through-hole 176 is located outside the plurality of through-holes 164. The through-holes 176 extend through the top surface 180 and the bottom surface 182a, i.e., the thickness of the first stator plate 106. Each through-hole 176 is sized to receive one of the stator rods 119.

[0034] Now turning to Figures 1 to 5 the second stator plate 108 shown in

[0035] The second stator plate 108 includes a first disassembly plate 186 attached to a second disassembly plate 188. The first disassembly plate 186 and the second disassembly plate 188 are fixedly attached to the second stator plate 108. The first disassembly plate 186 includes a slot-shaped opening 190 sized to receive one or more upper components of the fuel injector 102. The second disassembly plate 188 includes a slot-shaped opening 192 sized to receive one or more upper components of the fuel injector 102. The first disassembly plate 186 and the second disassembly plate 188 are arranged such that the slot-shaped opening 190 is a mirror image of the slot-shaped opening 192 so as to enable the disassembly and assembly of one or more upper components of the fuel injector 102. Thus, the first disassembly plate 186 and the slot-shaped opening 190 are configured to receive one or more upper components of the fuel injector 102 to disassemble these components. The second disassembly plate 188 and the slot-shaped opening 192 are configured to receive one or more upper components of the fuel injector 102 to assemble these components after the components have been cleaned and / or replaced with new components.The third stator plate 112 includes a plurality of through holes 200, with the illustrated embodiment including two through holes 200. The third stator plate 112 includes a plurality of fixing holes 202. When the third stator plate 112 is operably assembled with the first stator plate 106, the through holes 200 are positioned to align with the through holes 176. Each through hole 200 is located outside the plurality of fixing holes 202. The through holes 200 extend through the top surface 208 and the bottom surface 210, that is, through the thickness of the third stator plate 112. The size of each through hole 200 is set to receive one of the stator rods 119.

[0036] Each of the plurality of fixing holes 202 is configured to receive a fastener 204 to mount the centering ring 206 to the third stator plate 112 via a plurality of holes 216 arranged in the centering ring 206 to align with the plurality of fixing holes 202. Some examples of the fastener 204 include screws, bolts, or pins, to name a few. The illustrated embodiment includes four fixing holes 202, which are equidistantly arranged from each other and circumferentially arranged around the central hole 210 in the third stator plate 112.

[0037] The central hole 210 is aligned with the longitudinal axis or z-axis of the fuel injector tool 100. The size of the central hole 210 is set to receive a portion of the lower adjusting nut 220. The centering ring 206 rests on the top surface 208 of the third stator plate 112. The centering ring 206 includes a central hole 211, the size of which is similar to the central hole 210 in the third stator plate 112, such that when the centering ring 206 is assembled with the third stator plate 112, the centering holes 210 and 211 are aligned with each other for receiving a portion of the lower adjusting nut 220.

[0038] The third stator plate 112 further includes a plurality of mounting holes 230. In the illustrated embodiment, four mounting holes 230 are located in the third stator plate 112 to enable the fuel injector tool 100 to be mounted or attached to a work surface (not shown).

[0039] Now turning to Figures 6 to 13 , these figures are exemplary embodiments of the lower adjusting nut 220 and the upper adjusting nut 222 configured to be assembled between the second adjusting plate 110 and the third stator plate 112. The lower adjusting nut 220 and the upper adjusting nut 222 are configured to rotate to adjust the upstroke of the fuel injector 102 when the fuel injector 102 is assembled with the fuel injector tool 100. Rotating the lower adjusting nut 220 and the upper adjusting nut 222 clockwise respectively will decrease the upstroke of the fuel injector 102, and rotating counterclockwise will increase the upstroke of the fuel injector.

[0040] In Figures 6 to 9In one embodiment shown, the lower adjusting nut 220 is an M30×2 nut, where for each full rotation of the lower adjusting nut 220, the upward stroke of the fuel injector 102 changes by 2 mm. In some embodiments, this adjustment of the lower adjusting nut 220 is considered a coarse adjustment. The lower adjusting nut 220 includes a first end portion 270 separated from a second end portion 272 by an edge 275. The first end portion 270 includes a hexagonal head portion 274 and a rounded head portion 276. The second end portion 272 includes a rounded head portion 278 that extends into a recess 280. The lower adjusting nut 220 includes an opening 282 that spans along the length and central axis LA of the lower adjusting nut 220. The opening 282 includes a first portion 284 sized to receive a first end portion 300 of an adjusting nut 222. The opening 282 also includes a second portion 286 and a third portion 288, where the second portion 286 and the third portion 288 are sized to receive a fastener 290 ( Figure 5 shown). The fastener 290 is configured to engage and rotate an upper adjusting nut 222 to adjust the upward stroke of the fuel injector 102.

[0041] In Figures 10 to 13 one embodiment shown, the upper adjusting nut 222 is an M30×0.8 nut, and for each full rotation of the upper adjusting nut 222, the upward stroke of the fuel injector 102 changes by 0.8 mm. A 1° change in the rotation of the upper adjusting nut 222 will change the upward stroke of the fuel injector 102 by 2.22 μm. This adjustment of the upper adjusting nut 222 is a fine adjustment. The upper adjusting nut 222 includes a first end portion 300 separated from a second end portion 302 by an edge 304. The first end portion 300 has a solid cylinder with a length sufficient to engage the first portion 284 of the opening 282 of the lower adjusting nut 220. The second end portion 302 includes an opening 310 that spans along the length of the second end portion 302 and the central axis LA of the upper adjusting nut 222. The opening 310 is sized to receive the fastener 290. The opening 310 is configured to engage the injection end of the fuel injector to adjust the upward stroke of the fuel injector 102. The edge 304 has a hexagonal shape for receiving or engaging by a wrench or other tool to thereby rotate the upper adjusting nut 222.

[0042] The fuel injector tool 100 can be used to disassemble and assemble the fuel injector 102 in a single assembly of the fuel injector tool 100. The fuel injector tool 100 does not require several small additional fixtures to achieve partial disassembly and installation of the fuel injector 102; instead, the fuel injector tool 100 enables the disassembly and assembly of the fuel injector 102 in a single assembly. The disassembly and assembly of the fuel injector 102 enables inspection, repair, and adjustment of the fuel injector 102. The fuel injector tool 100 can be used to disassemble the fuel injector 102 into sub-components. The fuel injector tool 100 can be used to assemble the sub-components of the fuel injector 102 into a complete fuel injector 102. The fuel injector tool 100 can be used to perform coarse or large adjustments and / or fine or small adjustments on the upstroke of the fuel injector 102.

[0043] The fuel injector tool 100 employs the bolt thread engagement principle of a push and / or pull disassembly tool to disassemble or install the injector solenoid valve of the fuel injector 102. The fuel injector tool 100 employs a lower adjusting nut 220 and an upper adjusting nut 222 through holes, a screw reinforcement design, and maintains the easy rotation of the lower adjusting nut 220 and the upper adjusting nut 222 without interference from other components. The 2 mm main bolt or the thread machining distance accuracy of the lower adjusting nut 220 can be a coarse adjustment of the injector upstroke clearance. The 0.8 mm thread machining distance accuracy of the upper adjusting nut 222 can be a fine adjustment of the injector upstroke clearance to save work and reduce the error range.

[0044] The fuel injector tool 100 has a compact size and includes an upper component or a first adjusting plate 104, which is supported by three struts or a plurality of adjusting rods 118 to maintain the stability of the first adjusting plate 104. The first stator plate 106 is supported by two struts or a plurality of stator rods 119 to maintain the stability of the first stator plate 106. Each of the plurality of stator rods 119 is configured to receive one or more fasteners to assemble the plurality of stator rods 119 with the first stator plate 106 and the third stator plate 112.

[0045] The plurality of adjusting rods 118 extend through the first stator plate 106 and assist the plurality of stator rods 119 in maintaining the position or orientation of the first stator plate 106 relative to the first adjusting plate 104. Each of the plurality of adjusting rods 118 is configured to receive one or more fasteners to assemble the plurality of adjusting rods 118 with the first adjusting plate 104 and the second adjusting plate 110.

[0046] The plurality of adjusting rods 118 and the plurality of stator rods 119 are positioned to enable a worker to use a wrench or other tool on the fuel injector 102 and have a sufficient amount of clearance distance for the wrench or other tool to access the fuel injector 102.

[0047] The third stator plate 112 includes a plurality of mounting holes 230, and in the illustrated embodiment, the four mounting holes 230 enable the fuel injector tool 100 to be assembled to a workbench or other work surface. To attach the fuel injector 100 to the work surface, one or more fasteners are assembled with the plurality of mounting holes 230.

[0048] Figure 14 A method 500 of using the fuel injector tool 100 to disassemble and / or assemble a fuel injector 102 is provided. In step 502, the removal or disassembly of the upper screw of the fuel injector 102 is performed. In one embodiment, step 502 includes gently prying up the injector seal of the fuel injector 102 using an injector seal removal tool to separate the injector seal from the fuel injector 102. The injector seal is often damaged and must be discarded.

[0049] Next, step 504 includes removing or disassembling one or more upper components from the state assembled with the fuel injector 102. One of the upper components may include a solenoid. To perform this step, the fuel injector 102 is vertically mounted and fixed on the fuel injector tool 100, where the nozzle of the fuel injector 102 faces downward with respect to the longitudinal axis or z-axis of the fuel injector 102. Specifically, the fuel injector 102 is vertically inserted into the slot-shaped opening 190 of the first disassembly plate 186 of the fuel injector tool 100. A tool such as a flathead screwdriver can be used to remove the sealant from the pre-tightening adjustment screw. Another tool such as a 4mm hex key can be used to loosen the pre-tightening adjustment screw from the fuel injector 102 to form a partially assembled fuel injector 102'. Then, the partially assembled fuel injector 102' is removed from the slot-shaped opening 190 and positioned in the slot-shaped opening 166 such that the nozzle faces downward. The lower adjustment nut 220 is rotated counterclockwise to move the solenoid stator of the partially assembled fuel injector 102' upward. Then the solenoid stator is removed from the body of the partially assembled fuel injector 102'. Then the solenoid stator is removed from the body of the partially assembled fuel injector 102'.

[0050] Next, step 506 includes removing or disassembling the retainer from the state assembled with the fuel injector 102. The partially assembled fuel injector 102' is vertically placed and fixed in the slot-shaped opening 190 of the fuel injector tool 100, where the nozzle faces downward. A tool such as a hexagon-shaped tool is placed on the valve seat retainer of the partially assembled fuel injector 102', and a wrench or other tool is used to loosen it to remove the valve seat retainer from the partially assembled fuel injector 102'.

[0051] In step 508, the partially assembled fuel injector 102' is removed from the slot-shaped opening 166 and placed in the slot-shaped opening 190 such that the nozzle faces upward relative to the longitudinal axis or z-axis of the fuel injector 102. In one form, a tool such as a deep socket is positioned on the nozzle retaining cap of the partially assembled fuel injector 102'. Then a wrench or other tool is used to loosen and remove the nozzle retaining cap.

[0052] In step 510, the components removed from the fuel injector 102 in the previous steps 504, 506, and 508 are then cleaned. In some embodiments, the components are also inspected to determine if any components need to be replaced. In some embodiments, the components are placed in a clean tray in the pre-assembly order to facilitate assembly with the partially assembled fuel injector 102'.

[0053] In step 512, the cleaned components or replacement components from step 510 are installed in the slot-shaped opening 192 to reassemble the nozzle assembly of the fuel injector 102. In step 514, the cleaned needle or replacement needle from step 510 is installed or reassembled with the nozzle assembly of the fuel injector 102. In step 516, the cleaned retainer or replacement retainer from step 510 is assembled with the needle and nozzle assembly of the fuel injector 102. In step 518, the solenoid is installed on the fuel injector 102 and the upstroke of the fuel injector 102 is adjusted as described below in method 600 and Figure 15 as described in.

[0054] In step 520, the assembled fuel injector 102 is tested in a bench test as further described in method 600 and step 610. If the assembled fuel injector 102 passes the test of step 520, then in step 522, an injector seal is installed on the assembled fuel injector 102. After the injector seal is installed in the assembled fuel injector 102, then in step 524, the injector seal is glued in place in the fuel injector 102.

[0055] Now turning to Figure 15 , Figure 15 is method 600 for adjusting the upstroke length of the fuel injector 102 using the fuel injector tool 100 of Figures 1 to 13 In step 602, the lower component and the solenoid are assembled with the partially assembled fuel injector 102'. The partially assembled fuel injector 102' is secured to the fuel injector tool 100.

[0056] In one embodiment, step 602 includes placing the injector plunger, nozzle, and nozzle holder into the injector body in sequence and pre-tightening the nozzle holder by hand. Then the injector nozzle is vertically clamped into the customized fixture of the injector, a deep sleeve is placed on the nozzle holder, and the nozzle cap is tightened using a 200 Nm torque wrench. Then the operator determines whether the nozzle and / or injector plunger should be replaced.

[0057] In step 604, the dial indicator and stroke measurement tool are assembled with the partially assembled fuel injector 102' in the fuel injector tool 100. When pressing the stator, the operator will monitor the dial indicator after each adjustment to ensure that the stator is not pressed too tightly.

[0058] In step 606, the upper adjusting nut 222 is rotated to change the upper stroke of the partially assembled fuel injector 102'. Rotating the upper adjusting nut 222 clockwise will decrease the upper stroke of the fuel injector 102. Rotating the upper adjusting nut 222 counterclockwise will increase the upper stroke of the fuel injector 102. In one embodiment, the top surface 152 includes angular markings or identifiers 230 to assist and precisely control the adjustment angles of the lower adjusting nut 220 and the upper adjusting nut 222 for the upper stroke adjustment of the fuel injector 102. According to the measured value of the armature clearance, rotate the upper adjusting nut 222 clockwise to decrease the measured value of the armature clearance. Rotating the upper adjusting nut 222 counterclockwise will increase the measured value of the armature clearance. The standard armature clearance is 47 μm ± 3 μm. When measuring the armature clearance, it is necessary to ensure that the fuel injector 102 is stably fixed on the fuel injector tool 100. The operator can perform a stability test by pressing one or more fingers on the button at the top of the dial indicator. If the button cannot be pressed, it indicates a problem with the assembly of the fuel injector 102. If there is a problem, the fuel injector 102 should be disassembled and reassembled.

[0059] In step 608, the spring seat, armature pre-tightening spring, and pre-tightening adjustment screw are installed on the partially assembled fuel injector 102' to form the fully assembled fuel injector 102. If the high flow point is not good, the operator may need to use the fuel injector tool 100 to adjust the armature clearance. If the low flow point is not good, the operator may need to adjust the pre-tightening adjustment screw.

[0060] In one embodiment, the upper component is assembled with the partially assembled fuel injector 102', as described next for step 608. In other embodiments, the upper component may be assembled in a different manner. The fuel injector nozzle is installed vertically downward in the fuel injector tool 100. The operator may use tweezers to install the compression spring onto the plunger in the injector body. The tweezers may be used to install the plunger sleeve bushing onto the plunger in the injector body of the fuel injector 102. If the plunger seal needs to be replaced, the tweezers may be used to install the plunger seal into the injector body. The tweezers may be used to install the gasket and / or the PV seat into the injector body of the fuel injector 102. The operator also determines whether the PV seat needs to be replaced. The operator screws the seat retainer into the injector body by hand or using a tool. In some embodiments, the O-ring on the seat retainer must be replaced with a new O-ring. Then, the operator places an Allen key on the seat retainer and tightens the seat retainer using a torque wrench or other tool. Then the operator applies a small amount of industrial white petrolatum onto the valve ball and then places it into the valve ball seat so that it adheres to the valve ball seat. The operator uses tweezers or another tool to invert the entire valve ball and valve ball seat assembly onto the valve seat return hole. In some embodiments, the valve ball must be replaced with a new component. The operator uses tweezers to cover the overtravel spring onto the valve ball and valve ball seat assembly. The operator installs the armature and the armature plunger into the solenoid stator. In some embodiments, the O-ring of the solenoid stator must be replaced with a new O-ring.

[0061] In some embodiments, step 608 includes the operator smoothly installing the assembled solenoid stator assembly into the valve seat retainer of the injector and pressing the solenoid stator several times to ensure that the mating surfaces engage. The operator adjusts the angular position between the solenoid stator electrical terminals and the injector inlet connector. In one embodiment, the angular position is approximately 90° ± 1.5°. Then the operator vertically secures the injector to the fuel injector tool 100 with the nozzle facing down. Then the operator rotates the bottom or lower adjusting nut 220 clockwise to move the solenoid stator downward until the bottom or lower adjusting nut 220 is tightly locked. Then the operator combines the dial indicator with the armature lift measurement tool, places the dial indicator into the armature lift measurement tool, and after fully inserting the measuring needle, tightens the lower adjusting nut 220. The operator fully tightens the combination of the dial indicator and the armature lift measurement tool into the injector solenoid stator, resets the dial indicator to zero, and prepares for stroke measurement. Based on the measured value of the armature clearance, the operator rotates the upper adjusting nut 222 clockwise to reduce the measured value of the armature clearance. The operator rotates the upper adjusting nut 222 counterclockwise to increase the measured value of the armature clearance. The standard armature clearance is 47 μm ± 3 μm. When measuring the armature clearance, it is necessary to ensure that the fuel injector 102 is stably fixed to the fuel injector tool 100. If the operator's finger cannot press the button on the top of the dial indicator, it indicates that there is a problem with the assembly of the fuel injector 102 and the fuel injector 102 needs to be reassembled. The operator places the injector solenoid stator horizontally or slightly downward and uses tweezers to combine the spring seat and the armature preload spring and then installs them into the injector solenoid stator. Then, the operator places the preload adjustment screw of the injector into the threaded hole of the solenoid stator and uses a 4 mm hex key or other tool to rotate it clockwise between 6.5 and 7 turns. In some embodiments, the preload adjustment screw O-ring must be replaced with a new O-ring.

[0062] In step 610, the injector performance of the fully assembled fuel injector 102 is tested on a test machine. In one embodiment, the assembled fuel injector 102 is performance tested. The flow rate is tested to determine if it is within the required range. In step 612, the operator determines whether the injector performance of the fuel injector 102 is acceptable. If the injector performance is acceptable, then in step 614, method 600 ends and the major repair is completed or ended. If the test flow rate is within the required range and the test machine shows the result "normal", it indicates that the fuel injector performance test is qualified and no further operation is required.

[0063] If, at step 612, the injector performance is unacceptable, the method proceeds to step 604 to retest the injector performance of the fuel injector 102 on the fuel injector tool 100. If the flow rate is not within the required range at this time and the test machine displays the result "too high" or "too low", then the fuel injector flow rate needs to be reassembled and adjusted starting from step 604. In one embodiment, the high flow point is adjusted by adjusting the armature gap, and the low flow point is adjusted by adjusting the preload adjustment screw.

[0064] It is obvious from the above-presented drawings and text that various aspects of the present disclosure can be envisioned.

[0065] Various aspects of the present application are envisioned. According to one aspect, a fuel injector tool includes: a first adjustment plate that defines a slot-shaped opening sized to receive an upper portion of a fuel injector, the first adjustment plate defining a plurality of retaining holes positioned around the slot-shaped opening; a first stator plate that defines a plurality of through holes positioned around the slot-shaped opening, the slot-shaped opening sized to receive and hold an intermediate portion of the fuel injector; a second adjustment plate that defines an opening sized to receive and hold a lower portion of the fuel injector, the second adjustment plate defining a plurality of retaining holes positioned around the opening; a second stator plate that defines a central hole sized to receive and hold an adjustment nut, the second stator plate defining a plurality of through holes positioned around the central hole and further positioned to align with the plurality of through holes in the first stator plate when the second stator plate is operatively assembled with the first stator plate; a plurality of adjustment rods sized to be assembled with the plurality of retaining holes in the first and second adjustment plates to operatively connect the first adjustment plate to the second adjustment plate; and a plurality of stator rods sized to be assembled with the plurality of through holes in the first and second stator plates to operatively connect the first stator plate to the second stator plate.

[0066] In one embodiment, the slot-shaped opening in the first adjustment plate includes a retaining tab sized to receive and hold an upper portion of the fuel injector, wherein the upper portion of the fuel injector includes a body nozzle holder having a groove sized to mate with the retaining tab to hold the fuel injector in the slot-shaped opening.

[0067] In one embodiment, it further includes: a stator plate attached to the first stator plate, the stator plate including a first disassembly plate attached to a second disassembly plate.

[0068] In one embodiment, the first disassembly plate includes a slot-shaped opening sized to receive one or more upper components of a fuel injector.

[0069] In one embodiment, the second disassembly plate includes a slot-shaped opening sized to receive one or more upper components of a fuel injector.

[0070] In one embodiment, the first and second disassembly plates are arranged such that the slot-shaped opening in the first disassembly plate is a mirror image of the slot-shaped opening in the second disassembly plate.

[0071] In one embodiment, the second stator plate includes a plurality of fixing holes arranged such that when measured with respect to the longitudinal axis of the second stator plate, a plurality of through holes are positioned outside the plurality of fixing holes, wherein the plurality of fixing holes are sized to receive a plurality of fasteners for assembly together with the plurality of fixing holes.

[0072] In one embodiment, further comprising: a centering ring defining a plurality of holes sized to receive a plurality of fasteners, the centering ring being attached to the second stator plate with a plurality of fasteners, wherein the plurality of holes are arranged in the centering ring to align with the plurality of fixing holes in the second stator plate.

[0073] In one embodiment, the plurality of fixing holes are equidistantly arranged from each other and circumferentially arranged around a central hole in the second stator plate.

[0074] In one embodiment, the centering ring includes a central hole sized similarly to the central hole in the second stator plate such that when the centering ring is assembled with the second stator plate, the centering holes are aligned with each other to receive a portion of an adjusting nut.

[0075] In one embodiment, the central hole is aligned with the longitudinal axis of a fuel injector tool.

[0076] In one embodiment, the second stator plate includes a plurality of mounting holes configured to mount the fuel injector tool to a working surface with a plurality of fasteners.

[0077] In one embodiment, further comprising: an upper adjusting nut configured to be assembled with an adjusting nut, wherein the adjusting nut is a lower adjusting nut, and the upper adjusting nut and the lower adjusting nut are configured to be assembled between a second adjusting plate and the second stator plate.

[0078] In one embodiment, the lower adjusting nut and the upper adjusting nut are configured to rotate when the fuel injector is assembled with the upper adjusting nut to adjust the upstroke of the fuel injector.

[0079] In one embodiment, when the adjusting nut is rotated clockwise, the upward stroke of the fuel injector is reduced; and when the adjusting nut is rotated counterclockwise, the upward stroke of the fuel injector is increased.

[0080] In one embodiment, the lower adjusting nut is an M30*2 nut, and the upper adjusting nut is an M30*0.8 nut.

[0081] In one embodiment, the second adjusting plate includes a top surface having angular identifiers to identify the adjustment angles of the lower adjusting nut and / or the upper adjusting nut.

[0082] In one embodiment, each of the plurality of stator rods is configured to receive one or more fasteners to assemble the plurality of stator rods with the first stator plate and the second stator plate.

[0083] In one embodiment, each of the plurality of adjusting rods is configured to receive one or more fasteners to assemble the plurality of adjusting rods with the first adjusting plate and the second adjusting plate.

[0084] In one embodiment, a method of using a fuel injector tool to disassemble a fuel injector and then assemble the fuel injector.

[0085] In the foregoing description, certain relative terms may be used, such as "upward", "downward", "upper", "lower", "horizontal", "vertical", "left", "right", "proximal", "distal", and the like. When dealing with relative relationships, these terms are used, where applicable, to provide some clarity of description. However, these terms are not intended to imply absolute relationships, positions, and / or orientations. For example, with respect to an object, an "upper" surface can simply become a "lower" surface by flipping the object. Nevertheless, the object remains the same object.

[0086] References throughout this specification to "one embodiment", "an embodiment", or similar language mean that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearances of the phrases "in one embodiment", "in an embodiment", and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment. Similarly, the use of the term "embodiment" means an implementation having a particular feature, structure, or characteristic described in connection with one or more embodiments of the present disclosure, however, an implementation may be associated with one or more embodiments without an express correlation indicating otherwise.

[0087] The described features, structures, advantages, and / or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more embodiments and / or implementations. In the following description, numerous specific details are provided to afford a thorough understanding of embodiments of the subject matter of the present disclosure. Those skilled in the art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and / or methods of a particular embodiment or implementation. In some instances, the benefits of simplicity may provide operational and economic advantages, and the inventors contemplate that excluding certain elements described herein is within the scope of the invention to achieve such benefits. In other instances, additional features and advantages may be recognized in certain embodiments and / or implementations that may not be present in all embodiments or implementations. Additionally, in some cases, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more apparent from the following description and the appended claims, or may be learned by practicing the subject matter as set forth below.

[0088] Without departing from the spirit or essential characteristics of the subject matter, the subject matter may be embodied in other specific forms. The described embodiments are to be considered in all respects only illustrative and not restrictive. Thus, the scope of the invention is indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within the scope of the claims.

Claims

1. A fuel injector tool, comprising: A first adjustment plate defining a slot-shaped opening sized to receive an upper portion of a fuel injector, the first adjustment plate defining a plurality of retaining holes positioned around the slot-shaped opening; A first stator plate defining a plurality of through holes positioned around the slot-shaped opening, the slot-shaped opening sized to receive and retain an intermediate portion of the fuel injector; A second adjustment plate defining an opening sized to receive and retain a lower portion of the fuel injector, the second adjustment plate defining a plurality of retaining holes positioned around the opening; A second stator plate defining a central hole sized to receive and retain an adjusting nut, the second stator plate defining a plurality of through holes positioned around the central hole and further positioned to align with the plurality of through holes in the first stator plate when the second stator plate is operatively assembled with the first stator plate; A plurality of adjusting rods sized to be assembled with the plurality of retaining holes in the first and second adjustment plates to operatively connect the first adjustment plate to the second adjustment plate; And A plurality of stator rods sized to be assembled with the plurality of through holes in the first and second stator plates to operatively connect the first stator plate to the second stator plate.

2. The fuel injector tool according to claim 1, wherein the slot-shaped opening in the first adjustment plate includes a retaining tab sized to receive and retain the upper portion of the fuel injector, wherein the upper portion of the fuel injector includes a body nozzle holder having a groove sized to cooperate with the retaining tab to hold the fuel injector in the slot-shaped opening.

3. The fuel injector tool according to claim 1, further comprising: A stator plate attached to the first stator plate, the stator plate including a first removal plate attached to a second removal plate.

4. The fuel injector tool according to claim 3, wherein the first removal plate includes a slot-shaped opening sized to receive one or more upper components of the fuel injector.

5. The fuel injector tool according to claim 4, wherein the second removal plate includes a slot-shaped opening sized to receive one or more upper components of the fuel injector.

6. The fuel injector tool according to claim 5, wherein the first and second removal plates are arranged such that the slot-shaped opening in the first removal plate is a mirror image of the slot-shaped opening in the second removal plate.

7. The fuel injector tool according to claim 1, wherein the second stator plate includes a plurality of fixing holes arranged such that when measured with respect to the longitudinal axis of the second stator plate, the plurality of through holes are positioned outside the plurality of fixing holes, and wherein the plurality of fixing holes are sized to receive a plurality of fasteners for assembly with the plurality of fixing holes.

8. The fuel injector tool according to claim 7, further comprising: A centering ring defining a plurality of holes sized to receive a plurality of fasteners, the centering ring being attached to the second stator plate with the plurality of fasteners, wherein the plurality of holes are arranged in the centering ring to align with the plurality of fixing holes in the second stator plate.

9. The fuel injector tool according to claim 8, wherein the plurality of fixing holes are equidistantly arranged from each other and circumferentially arranged around the central hole in the second stator plate.

10. The fuel injector tool according to claim 8, wherein the centering ring includes a central hole sized similar to the central hole in the second stator plate such that when the centering ring is assembled with the second stator plate, the centering holes are aligned with each other to receive a portion of the adjusting nut.

11. The fuel injector tool according to claim 1, wherein the central hole is aligned with the longitudinal axis of the fuel injector tool.

12. The fuel injector tool according to claim 1, wherein the second stator plate includes a plurality of mounting holes configured to mount the fuel injector tool to a working surface with a plurality of fasteners.

13. The fuel injector tool according to claim 1, further comprising: An upper adjusting nut configured to be assembled with the adjusting nut, wherein the adjusting nut is a lower adjusting nut, and the upper adjusting nut and the lower adjusting nut are configured to be assembled between the second adjusting plate and the second stator plate.

14. The fuel injector tool according to claim 13, wherein the lower adjusting nut and the upper adjusting nut are configured to rotate when the fuel injector is assembled with the upper adjusting nut to adjust the upstroke of the fuel injector.

15. The fuel injector tool according to claim 14, wherein when the upper adjusting nut is rotated clockwise, the upstroke of the fuel injector is decreased; and wherein when the upper adjusting nut is rotated counterclockwise, the upstroke of the fuel injector is increased.

16. The fuel injector tool according to claim 13, wherein the lower adjusting nut is an M30*2 nut, and wherein the upper adjusting nut is an M30*0.8 nut.

17. The fuel injector tool according to claim 13, wherein the second adjusting plate includes a top surface having an angular identifier to identify the adjustment angle of the lower adjusting nut and / or the upper adjusting nut.

18. The fuel injector tool according to claim 1, wherein each of the plurality of stator rods is configured to receive one or more fasteners to assemble the plurality of stator rods with the first stator plate and the second stator plate.

19. The fuel injector tool according to claim 1, wherein each of the plurality of adjusting rods is configured to receive one or more fasteners to assemble the plurality of adjusting rods with the first adjusting plate and the second adjusting plate.

20. A method of using the fuel injector tool according to any one of claims 1 to 19 to disassemble the fuel injector and then assemble the fuel injector.

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