Deformable Cap Nut for Fuel Injector Sensor Alignment
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Solution Overview
Problem
In fuel injector assembly, the angular misalignment between the cap nut's pressure sensor and the nozzle holder body connection point causes issues with signal cable alignment, especially due to manufacturing tolerances and space restrictions, making automated assembly challenging.
Innovation Solution
A fastening member with a deformable portion that allows relative movement between its portions, enabling angular alignment of the cap nut's connection point with the nozzle holder body connection point during assembly, by applying a clamping force and then further turning to align the two points without increasing the clamping force excessively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cap nut is screwed on to the nozzle holder body during assembly, then the components are fastened together, but the angular misalignment between the pressure sensor and connection point causes signal cable alignment issues
Solution Approach 1:
The cap nut is designed with a deformable portion that allows dynamic adjustment of the first portion's angular position relative to the second portion. After the cap nut is screwed onto the nozzle holder body, the deformable portion enables further relative rotation between the first and second portions, allowing the connection point on the first portion to be aligned with the connection point on the nozzle holder body without compromising the fastening reliability.
2Extent of automation
If the connection points are angularly misaligned, then automated assembly is facilitated, but signal cable routing becomes complex and non-axial
Solution Approach 1:
The deformable portion of the cap nut enables dynamic angular adjustment of the connection point on the first portion relative to the connection point on the nozzle holder body. This dynamic adjustment capability allows the connection points to be aligned in the axial direction, facilitating simple signal cable routing and reducing device complexity while maintaining automated assembly capability.
3Ease of manufacture
If manufacturing tolerances cause varying angular spacing, then production flexibility is improved, but consistent alignment between components becomes difficult
Solution Approach 1:
The deformable portion of the cap nut provides a dynamic adjustment mechanism that compensates for variations in angular spacing caused by manufacturing tolerances. After the cap nut is assembled, the deformable portion allows the first portion to rotate relative to the second portion, enabling consistent alignment of connection points regardless of the initial angular positioning of the pressure sensor, thus maintaining manufacturing precision while preserving production flexibility.
Solution Approach 2:
The cap nut utilizes changes in the physical state of the deformable portion (from rigid to deformable) to enable angular adjustment. This parameter change allows the connection point on the first portion to be repositioned angularly relative to the connection point on the nozzle holder body, compensating for manufacturing tolerance variations and ensuring consistent alignment.
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
Enables the alignment of the cap nut's connection point with the nozzle holder body connection point, facilitating the use of an axial signal cable and ensuring a secure, automated assembly process, even with varying angular spacings due to manufacturing tolerances.
Implementation Method 1
a deformable portion intermediate the first and second portions... The deformable portion allows relative movement of the first and second portions of the fastening member
Data Source
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AI summary
A fastening member (100) for fastening a first component (118) to a second component (110) in an end-to-end configuration along a common axis (A) is disclosed. The fastening member (100) comprises a first portion (124) having a threaded region for engagement with a corresponding threaded region (120) of the first component (118), a second portion (126) for applying a retaining force to the second component (110) to hold the first and second components (118, 110) in sealing engagement, and a deformable portion (130) intermediate the first and second portions (124, 126). The fastening member is particularly suitable for use as a cap nut in a fuel injector of the type having a cylinder pressure sensor integrated into the cap nut.