Dual-Needle Fuel Injector Layout for High-Pressure Chamber Strength
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Solution Overview
Problem
Existing fuel injectors for large internal combustion engines, particularly dual-fuel engines, face challenges in achieving high operational reliability and ease of manufacture while handling different fuel types under high operating pressures.
Innovation Solution
The fuel injector design incorporates separate first and second fuel storage chambers arranged side by side in the transverse direction with overlapping longitudinal arrangements, featuring different diameters and lengths to reduce stress and oscillations, and utilizes autofrettage for internal pressure resistance, enhancing operational reliability and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If fuel storage chambers are arranged axially one after another, then the injector body becomes longer, but the structural strength and pressure resistance deteriorate
Solution Approach 1:
The patent transitions from axial arrangement (one-dimensional sequence) to radial arrangement (two-dimensional lateral distribution) of fuel storage chambers. The first and second fuel storage chambers are positioned side-by-side in the radial direction rather than one after another axially, reducing the axial length while improving structural strength through shorter chamber diameters that are easier to autofrettage.
2Volume of stationary object
If fuel storage chambers have larger diameter, then the storage capacity increases, but the stress and manufacturing complexity increase under high pressure
Solution Approach 1:
The patent redistributes fuel storage capacity from axial length to radial arrangement. By placing chambers side-by-side radially with optimized smaller diameters, the design achieves required storage volume while maintaining manufacturable chamber dimensions that can be effectively autofrettaged.
Solution Approach 2:
The patent divides the fuel storage system into multiple separate chambers (first fuel storage chamber for diesel, second fuel storage chamber for gas fuel) arranged radially. This segmentation allows each chamber to be independently optimized for its specific fuel type and pressure requirements, with smaller diameters that are easier to manufacture with appropriate wall thicknesses.
3Adaptability or versatility
If the injector handles multiple fuel types under high pressure, then the versatility increases, but the operational reliability and stress management become more difficult
Solution Approach 1:
The patent implements separate, dedicated storage chambers for different fuel types (diesel in first chamber, gas fuel in second chamber). This segmentation isolates each fuel system, allowing independent pressure management and reducing cross-contamination risks, thereby improving operational reliability while maintaining multi-fuel versatility.
Solution Approach 2:
The patent optimizes each fuel storage chamber's dimensions and wall thickness according to its specific fuel type and operating pressure requirements. The first chamber for diesel and second chamber for gas fuel can have different structural characteristics tailored to their respective pressures, enhancing overall system reliability.
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 design ensures high operational reliability and reduces manufacturing costs by minimizing stress and oscillations, allowing for efficient fuel injection of ignitable and inert fuels in dual-fuel engines.
Implementation Method 1
It is possible to achieve the desired internal pressure resistance of the fuel storage chambers by means of autofrettage
Data Source
Figure 1
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AI summary
Fuel injector (10) of an internal combustion engine, designed to supply fuel to a combustion chamber of a cylinder of the internal combustion engine, comprising a first nozzle needle (14) movably guided in a first needle guide (12), which interacts with first fuel injection ports (16) such that, depending on its position, the first nozzle needle (14) either releases or blocks a fuel flow of a first fuel through the first fuel injection ports (16), with a second nozzle needle (15) movably guided in a second needle guide (13), which interacts with second fuel injection ports (17) such that, depending on its position, the second nozzle needle (15) either releases or blocks a fuel flow of a second fuel through the second fuel injection ports (17), with at least one first fuel storage chamber (22) integrated therein for the first fuel,with at least one second fuel storage chamber (23) integrated into the same for the second fuel, wherein the at least one first fuel storage chamber (22) and the at least one second fuel storage chamber (23) are arranged side by side in the transverse or radial direction of the fuel injector (10) and overlap in the longitudinal or axial direction of the fuel injector (10). Fig. 1,