Method of remanufactuing electronically controlled unit injector nozzle control valve assembly

Abstract

A method of remanufacturing a fuel injector nozzle control valve assembly is provided. The method includes obtaining a used nozzle control valve assembly (40). The used nozzle control valve assembly includes a used guide (42), a used pin (44) received in the guide, and a used armature (48) mounted on the pin. The method further includes the steps of: disassembling the used nozzle control valve assembly (40) to isolate the used guide (42); inspecting the used guide (42); and providing a new pin (44') that meets original specifications. If the used guide (42) passes the inspection, the method further includes the steps of: inserting the new pin (44') into the used guide (42); providing a new armature (48') that meets original specifications; and mounting the new armature (48') onto the new pin (44') inserted into the used guide (42) to assembly a remanufactured nozzle control valve assembly (40').

Description

METHOD OF REMANUFACTUING ELECTRONICALLY CONTROLLED UNIT INJECTOR NOZZLE CONTROL VALVE ASSEMBLY CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Application No. 63 / 676,488, filed July 29, 2024, the disclosure of which is incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] The disclosure generally relates to fuel injectors and, more specifically, to remanufacturing of fuel injector nozzle control valves.BACKGROUND OF THE INVENTION

[0003] Electronically controlled unit injectors (EUls) include a nozzle control valve (NCV) that is adjacent the nozzle tip assembly of the injector. The nozzle control valve is itself an assembly that opens and closes to allow fluid such as fuel to selectively pass to the nozzle tip assembly. More particularly, as shown by example in Figure 1 , the nozzle control valve includes three main component parts: a guide, a pin, and an armature. In an assembled disposition, the pin is matched with and retained in a central bore that is formed in and through the guide in an axial direction. An armature is mounted on an axial end of the pin, and the pin moves within the bore between open and closed positions via an applied electromagnetic force that acts on the armature. As shown in Figure 2, the guide has a single high pressure sealing seat that forms a first, upper valve seal with the pin when the pin is located in the open position. In the closed position, the pin forms a second, lower valve seal with the face of a separate nozzle assembly that is disposed below the nozzle control valve.

[0004] Conventionally, all core, used nozzle control valves are discarded from used injectors, and completely new nozzle control valves are used to remanufacture the injectors. However, the use of new nozzle control valves is expensive. Further, reuse of used nozzle control valves has not yielded a sufficient number of acceptably operational units. Thus, used nozzle control valves are considered to be waste and the component materials are recycled rather than the nozzle control valves being reused. Therefore, a need exists for a method of remanufacturing nozzle control valves for use in remanufactured injectors.BRIEF SUMMARY

[0005] A method of remanufacturing a fuel injector nozzle control valve assembly is provided. The nozzle control valve assembly includes a guide, a pin configured to be received in the guide, and an armature configured to be mounted on the pin. The method includes obtaining a used nozzle control valve assembly. The used nozzle control valve assembly includes a used guide, a used pin received in the used guide, and a used armature mounted on the used pin. The method further includes disassembling the used nozzle controlvalve assembly to isolate the used guide. The method further includes inspecting the used guide. The method further includes providing a new pin that meets original specifications. If the used guide passes the inspection, the method further includes inserting the new pin into the used guide. The method further includes providing a new armature that meets original specifications, and mounting the new armature onto the new pin inserted into the used guide to assemble a remanufactured nozzle control valve assembly.

[0006] In specific embodiments, the method further includes the step of washing used guide prior to the step of inspecting the used guide.

[0007] In specific embodiments, the step of inspecting the used guide includes visually inspecting the used guide.

[0008] In specific embodiments, subsequent to inserting the new pin into the used guide, the method further includes the step of performing a lift measurement of the new pin in the used guide.

[0009] In specific embodiments, subsequent to inserting the new pin into the used guide, the method further includes the step of performing a high pressure valve test on the new pin in the used guide.

[0010] In specific embodiments, the step of mounting the new armature on the new pin includes interference fitting the new armature onto the new pin.

[0011] In specific embodiments, one or both of the used pin and the used armature are scrapped.

[0012] In specific embodiments, the used nozzle control valve assembly is obtained from an engine.

[0013] In specific embodiments, the method further includes the step of installing the remanufactured nozzle control valve assembly in a fuel injector.

[0014] In particular embodiments, the method further includes the step of installing the fuel injector including the remanufactured nozzle control valve assembly in an engine.

[0015] A remanufactured nozzle control valve assembly obtained by the method is also provided.DESCRIPTION OF THE DRAWINGS

[0016] Various advantages and aspects of this disclosure may be understood in view of the following detailed description when considered in connection with the accompanying drawings, wherein:

[0017] Figure 1 is an exploded view of a nozzle control valve assembly;

[0018] Figure 2 is a partial, sectional view of an injector including the nozzle control valve assembly of Figure 1 ;

[0019] Figure 3 is a flowchart of a method of remanufacturing a nozzle control valve assembly in accordance with embodiments of the disclosure;

[0020] Figure 4 is a perspective view of a used, reclaimed guide of the nozzle control valve assembly;

[0021] Figure 5 is a perspective view of a new pin inserted into the used, reclaimed guide; and

[0022] Figure 6 is a perspective view of a remanufactured nozzle control valve assembly including the used, reclaimed guide, the new pin, and a new armature.DETAILED DESCRIPTION OF THE INVENTION

[0023] A method of remanufacturing a fuel injector nozzle control valve assembly is provided. The method allows for the reclamation and remanufacturing of fuel injector components that were previously unusable. The method results in a remanufactured nozzle control valve at a lower cost than replacing the used nozzle control valve with a new assembly.

[0024] Referring to Figure 3, wherein like numerals indicate corresponding parts throughout the several views, the method is generally designated as 110. At step S1 12, the method first includes obtaining a used nozzle control valve assembly. A “used” nozzle control valve assembly is one that has been installed into a fuel injector that is associated with an engine (e.g., an internal combustion engine) and utilized during operation of the engine. Thus, the “used” nozzle control valve assembly is reclaimed from an existing engine that has been operational. The “used” nozzle control valve assembly also may be one that is worn or is otherwise in an inoperable state, although such is not necessarily the case. As shown by way of example in Figure 1 , the used nozzle control valve assembly 40 includes a used guide 42, a used pin 44 received in a central bore 46 formed in the used guide 42, and a used armature 48 mounted on the used pin 44. The used nozzle control valve assembly 40 may be obtained from a used fuel injector nozzle assembly 50 as shown by way of example in Figure 2.

[0025] At step S114, the method next includes disassembling the used nozzle control valve assembly 40 to isolate the used guide 42. The used guide 42 of the used nozzle control valve assembly is kept and further processed in the method, while the used pin 44 and used armature 48 of the used nozzle control valve assembly are not further utilized in the method and may be scrapped and / or otherwise recycled or disposed of. The reclaimed, used guide 42 may then be washed and then subsequently at step S116 subjected to an inspection such as a visual inspection for any noticeable structural defects. Typically, the guide seat on the used guide 42 as well as the bore geometry of the central bore 46 in the used guide 42 should be in good to new condition for a majority of the inspected used guides. If the used guide 42 passes the inspection at step S1 16, then the used guide 42 is kept and advanced in the remanufacturing process. The isolated, used guide 42 is shown in Figure 4. If the usedguide should happen to fail the inspection, then it is scrapped and the process returns to the first step in the method.

[0026] At step S118, the method next includes providing a new pin 44’ that meets original specifications. The new pin 44’ can be manufactured in the same way as the original, used pin 44 that was removed from the used guide 42. The pin manufacturing process may include, for example: pushfit and throat grinding of the pin; stem, collar, and top seat griding of the pin; deburring of the pin; washing of the pin; and coating of a portion of the pin with a coating such as a diamond-like carbon (DLC) coating. By “new” pin it is meant that the pin 44’ is not the original pin 44 that was used in the reclaimed, used guide 42. Also, a “new” pin is one that has not been previously used or assembled into a guide. A “new” pin is thus a pin that is fabricated for a first use in a nozzle control valve assembly.

[0027] At step S120, the new pin 44’ provided and obtained in the proceeding step is matched with and inserted into the central bore in the used guide 42 that has passed the inspection at step S1 16. The matched new pin 44’ and used guide 42 are shown in Figure 5. Subsequent to inserting the new pin 44’ into the used guide 42, the method may further include at step S122 performing a lift measurement of the new pin 44' in the used guide 42. Assuming the combination of the new pin 44’ in the used guide 42 passes the lift measurement, the method may further include at step S124 performing a high pressure valve test on the new pin 44’ in the used guide 42. If the new pin 44’ and used guide 42 pass the high pressure valve test, then the used guide with the new pin inserted therein may be washed and the method proceeds to the next step.

[0028] At step S126, the method further includes providing a new armature 48’ that meets original specifications. The new armature 48’ can be manufactured in the same way as the original, used armature 48 that was removed from the used guide 42. By “new” armature it is meant that the new armature 48’ is not the original armature 48 that was used in the reclaimed guide 42. Also, a “new” armature is one that has not been previously used or assembled into a nozzle control valve. A “new” armature is thus an armature that is fabricated for a first use in a nozzle control valve assembly.

[0029] At step S128, the method next includes mounting the new armature 48’ onto the new pin 42’ inserted into the used guide 42 to assemble a remanufactured nozzle control valve assembly 40’ as shown in Figure 6. The mounting may be performed, for example, by interference fitting the new armature 48’ on the new pin 42’. The nozzle control valve assembly 40’ shown in Figure 6 also includes dowel rods 50 inserted into apertures in the used guide 42. After assembly of the remanufactured nozzle control valve assembly 40’, the remanufactured nozzle control valve assembly 40’ can then be installed into a fuel injector such as shown by way of example in Figure 2. The dowel rods 50 facilitate the installation of the nozzle control valve assembly 40’ in the fuel injector assembly. Further, the fuel injectorincluding the remanufactured nozzle control valve assembly 40’ can be installed into an engine.

[0030] It is to be understood that the appended claims are not limited to express and particular compounds, compositions, or methods described in the detailed description, which may vary between particular embodiments which fall within the scope of the appended claims. With respect to any Markush groups relied upon herein for describing particular features or aspects of various embodiments, different, special, and / or unexpected results may be obtained from each member of the respective Markush group independent from all other Markush members. Each member of a Markush group may be relied upon individually and or in combination and provides adequate support for specific embodiments within the scope of the appended claims.

[0031] Further, any ranges and subranges relied upon in describing various embodiments of the present invention independently and collectively fall within the scope of the appended claims, and are understood to describe and contemplate all ranges including whole and / or fractional values therein, even if such values are not expressly written herein. One of skill in the art readily recognizes that the enumerated ranges and subranges sufficiently describe and enable various embodiments of the present invention, and such ranges and subranges may be further delineated into relevant halves, thirds, quarters, fifths, and so on. As just one example, a range “of from 0.1 to 0.9” may be further delineated into a lower third, i.e., from 0.1 to 0.3, a middle third, i.e., from 0.4 to 0.6, and an upper third, i.e., from 0.7 to 0.9, which individually and collectively are within the scope of the appended claims, and may be relied upon individually and / or collectively and provide adequate support for specific embodiments within the scope of the appended claims. In addition, with respect to the language which defines or modifies a range, such as “at least,” “greater than,” “less than,” “no more than,” and the like, it is to be understood that such language includes subranges and / or an upper or lower limit. As another example, a range of “at least 10” inherently includes a subrange of from at least 10 to 35, a subrange of from at least 10 to 25, a subrange of from 25 to 35, and so on, and each subrange may be relied upon individually and / or collectively and provides adequate support for specific embodiments within the scope of the appended claims. Finally, an individual number within a disclosed range may be relied upon and provides adequate support for specific embodiments within the scope of the appended claims. For example, a range “of from 1 to 9” includes various individual integers, such as 3, as well as individual numbers including a decimal point (or fraction), such as 4.1 , which may be relied upon and provide adequate support for specific embodiments within the scope of the appended claims.

[0032] The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the spirit and broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordancewith the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements by ordinal terms, for example “first,” “second,” and “third,” are used for clarity, and are not to be construed as limiting the order in which the claim elements appear. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular.

Claims

CLAIMSWhat is claimed is:1 . A method of remanufacturing a fuel injector nozzle control valve assembly, the nozzle control valve assembly comprising a guide, a pin configured to be received in the guide, and an armature configured to be mounted on the pin, the method comprising: obtaining a used nozzle control valve assembly (40), the used nozzle control valve assembly including a used guide (42), a used pin (44) received in the used guide, and a used armature (48) mounted on the used pin (44); disassembling the used nozzle control valve assembly (40) to isolate the used guide (42); inspecting the used guide (42); providing a new pin (44’) that meets original specifications; if the used guide (42) passes the inspection, inserting the new pin (44’) into the used guide (42); providing a new armature (48’) that meets original specifications; mounting the new armature (48’) onto the new pin (44') inserted into the used guide (42) to assemble a remanufactured nozzle control valve assembly (40’).

2. The method of claim 1 , further including the step of washing used guide (42) prior to the step of inspecting the used guide.

3. The method of claim 1 , wherein the step of inspecting the used guide (42) includes visually inspecting the used guide.

4. The method of claim 1 , wherein subsequent to inserting the new pin (44’) into the used guide (42), the method further includes the step of performing a lift measurement of the new pin in the used guide.

5. The method of claim 1 , wherein subsequent to inserting the new pin (44’) into the used guide (42), the method further includes the step of performing a high pressure valve test on the new pin in the used guide.

6. The method of claim 1 , wherein the step of mounting the new armature (48’) on the new pin (44’) includes interference fitting the new armature onto the new pin.

7. The method of claim 1 , wherein one or both of the used pin (44) and the used armature (48) are scrapped.

8. The method of claim 1 , wherein the used nozzle control valve assembly (40) is obtained from an engine.

9. The method of claim 1 , further including the step of installing the remanufactured nozzle control valve assembly (40’) in a fuel injector.

10. The method of claim 9, further including the step of installing the fuel injector including the remanufactured nozzle control valve assembly (40’) in an engine.

11. A remanufactured nozzle control valve assembly (40’) obtained by the method of claim 1 .

Images