Coiled Wave Spring Fixing for Compact Diaphragm Dampers
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Solution Overview
Problem
Existing diaphragm damper devices in high-pressure fuel pumps face challenges in stably and rigidly fixing diaphragm dampers due to limited space, with wave washers having low yield, high manufacturing costs, and difficulty in shape modifications.
Innovation Solution
A coiled wave spring is used, featuring flat seat windings with a larger outer diameter than the coil portion, allowing stable deflection and strong spring force, integrated with diaphragm dampers and coupling members for secure fixation, enabling easy assembly and adaptation to different cover shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a wave washer is used to fix the diaphragm damper, then the device can be fixed in limited space, but the fixing stability and rigidity are insufficient
Solution Approach 1:
The wave washer is divided into multiple windings (first winding, second winding, third winding) with different functions. The first winding provides fixing to the diaphragm damper, the second winding provides fixing to the cover, and the third winding provides additional stabilization. This segmentation allows each part to perform its specific function optimally within the limited space.
Solution Approach 2:
Different portions of the wave washer are given different properties: the first winding has a larger outer diameter for stable fixing to the diaphragm damper, the second winding is positioned for cover attachment, and the third winding provides additional support. This local differentiation of properties enhances overall fixing reliability while maintaining compact dimensions.
2Volume of moving object
If a wave washer is used to fix the diaphragm damper, then the device can be fixed in limited space, but the manufacturing cost is high and yield is low
Solution Approach 1:
The wave washer parameters (number of windings, outer diameters, thickness) are optimized to achieve the required fixing strength with fewer material resources. The specific configuration of three windings with progressively smaller outer diameters allows efficient use of material while maintaining high fixing reliability, thereby reducing manufacturing cost and improving yield.
3Volume of moving object
If a wave washer is used to fix the diaphragm damper, then the device can be fixed in limited space, but shape modifications are difficult
Solution Approach 1:
The wave washer is segmented into multiple windings that can be independently designed with different outer diameters and spacing. This segmentation allows flexible adaptation to different cover shapes and sizes by adjusting the parameters of individual windings without changing the overall compact structure.
Solution Approach 2:
The wave washer design allows easy modification of parameters such as the number of windings, their outer diameters, and spacing between them. This parametric flexibility enables rapid adaptation to different application requirements and cover geometries while maintaining the compact form factor.
4Reliability
If multiple diaphragm dampers are stacked in the fuel chamber, then the pulsation reduction effect is enhanced, but the height of the fixing means is limited to extremely small dimensions
Solution Approach 1:
Instead of increasing the height of the wave washer in the vertical direction, the design utilizes the radial dimension by creating multiple windings with different outer diameters. This dimensional transformation allows the wave washer to provide sufficient fixing strength for multiple stacked dampers without increasing the overall height, thereby accommodating the limited vertical space in the fuel chamber.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coiled wave spring provides a strong, stable spring force for fixing diaphragm dampers, reducing manufacturing costs, and allowing for easy shape changes, while ensuring even spring force distribution and easy coupling with other components.
Implementation Method 1
The coiled wave spring is configured to fix the diaphragm damper to the housing with its elastic force
Data Source
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AI summary
A coiled wave spring used by a diaphragm damper device and arranged in a fuel chamber defined by a housing and a cover is provided. The coiled wave spring is configured to be arranged between a diaphragm damper of the diaphragm damper device and the cover. The coiled wave spring is configured to fix the diaphragm damper to the housing with its elastic force. The coiled wave spring includes a coil portion, a winding initiation portion, and a winding termination portion. The winding initiation portion and the winding termination portion form flat seat windings. The seat windings each have a larger outer diameter than the coil portion. One of the seat windings is configured to be fixed to the diaphragm damper.