Common Rail Fuel Pump Integrated Valve Assembly
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Solution Overview
Problem
Conventional high pressure fuel supply pumps for gasoline common rail injection systems face challenges with high costs, difficulty in pre-testing, and restricted radial location of the outlet fitting due to separate outlet check and pressure relief valves.
Innovation Solution
Integrating the outlet check valve and pressure relief valve into a single fitting assembly within the high pressure fuel pump, allowing for lower system costs, pre-testing of valve functions, and improved flexibility in radial location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate outlet check valve and pressure relief valve are used within the housing, then the pressure relief function is provided, but the system cost increases and pre-testing becomes difficult
Solution Approach 1:
The patent combines the outlet check valve and pressure relief valve into a single integrated valve assembly. The valve body contains both valve functions with shared components such as the spring mechanism and seating surfaces, eliminating the need for separate valve housings and reducing overall system complexity while maintaining both pressure relief and check valve functions.
Solution Approach 2:
The integrated valve assembly serves multiple functions simultaneously: it acts as both an outlet check valve to prevent backflow and a pressure relief valve to limit maximum system pressure. The single assembly handles both protective functions that were previously required from separate devices, improving efficiency and reducing cost.
2Reliability
If separate outlet check valve and pressure relief valve are used within the housing, then the pressure relief function is provided, but pre-testing becomes difficult
Solution Approach 1:
By integrating both valve functions into a single assembly with shared mounting interfaces and actuation mechanisms, the patent enables the entire valve system to be tested as one unit during manufacturing. This unified structure allows pre-assembly testing of both check valve and pressure relief valve functions before installation, simplifying quality control procedures.
3Reliability
If separate outlet check valve and pressure relief valve are used within the housing, then the pressure relief function is provided, but the radial location of the outlet fitting is restricted
Solution Approach 1:
The integrated valve assembly consolidates both valve functions into a single compact unit with a unified outlet fitting. This combination frees the outlet fitting from the radial location constraints that existed when two separate valves were required, allowing greater flexibility in positioning and routing the fuel outlet to optimize system layout and performance.
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
This configuration reduces system costs, simplifies pre-testing, and enhances flexibility in fitting placement, improving overall pump efficiency and reliability.
Implementation Method 1
the pump must incorporate an outlet check valve to prevent pressure bleed back from the rail while the pump is in the intake stroke cycle
Implementation Method 2
the pressure relief valve must be in hydraulic communication with the rail, i.e., in parallel with the pump flow
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A high pressure piston fuel pump having a discharge check valve between the pumping chamber and a pressurized fuel reservoir and a pressure relief valve between the fuel reservoir and a passageway in the housing, wherein the discharge check valve and the pressure relief valve are contained within a single fitting assembly affixed at the pump housing. A first end flow passage is in fluid communication with the pumping chamber and provides an inlet to the discharge check valve and an outlet from the pressure relief valve. A second end flow passage is in fluid communication with the fuel reservoir and provides an outlet for the discharge check valve and an inlet for the pressure relief valve. Advantages include the ability to pre-test the outlet check and pressure relief prior to assembly into the pump housing, and improved flexibility of the outlet fitting location.