Flow Control System for Diesel Fuel Injectors
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Solution Overview
Problem
Existing flow control systems for diesel fuel injectors face challenges in balancing controllability and hydraulic efficiency, with 3-way solenoid actuators being costly and complex, and 2-way solenoid actuators experiencing high control leakage, leading to conflicts between response time and efficiency.
Innovation Solution
A flow control system incorporating a 2-way control valve with extended mechanical resilient means to the shuttle valve, a poppet restriction, and a fuel injection nozzle, which reduces control leakage and enhances responsiveness by utilizing a spring-closed nozzle and spill valve configurations to manage pressure differentials and leakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a 3-way solenoid actuator is used, then control precision is improved, but cost and complexity increase
Solution Approach 1:
The patent extracts and eliminates the complex 3-way solenoid actuator from the system, replacing it with a simpler 2-way solenoid actuator combined with a shuttle valve mechanism. This extraction of the problematic component resolves the contradiction by maintaining control precision through the alternative mechanism while significantly reducing cost and complexity.
Solution Approach 2:
The patent uses a shuttle valve that copies the function of a 3-way valve's flow control capability but achieves it through a simpler 2-way valve configuration. The shuttle valve replicates the necessary flow management functions without requiring the complex actuator, thus maintaining control precision while reducing device complexity.
2Device complexity
If a 2-way solenoid actuator is used, then cost and durability are improved, but control leakage increases
Solution Approach 1:
The patent introduces a shuttle valve as an intermediary component between the 2-way solenoid actuator and the hydraulic circuit. This intermediary mechanism manages and reduces control leakage by providing a controlled path for fluid flow, allowing the simpler 2-way actuator to function effectively without the penalties of high control leakage.
Solution Approach 2:
The patent employs hydraulic principles through the shuttle valve and control chamber configuration to manage fluid flow and pressure. By using hydraulic means to control the shuttle valve positioning and sealing, the system reduces control leakage while maintaining the simplicity and cost-effectiveness of the 2-way solenoid actuator.
3Loss of energy
If control leakage is reduced, then hydraulic efficiency is improved, but response time increases
Solution Approach 1:
The patent implements preliminary action through the pre-configured shuttle valve and control chamber arrangement that prepares the hydraulic circuit for rapid response. The shuttle valve's pre-positioning and the control chamber's pre-pressurization enable the system to achieve both low control leakage and fast response time by having the system ready to act immediately when needed.
Solution Approach 2:
The patent uses dynamic control through the shuttle valve mechanism that can rapidly transition between different flow states. The dynamic positioning of the shuttle valve and the associated pressure differentials allow the system to adapt quickly to control commands while maintaining low leakage during steady-state operation, thus achieving both hydraulic efficiency and fast response time.
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 system achieves reduced control leakage, improved responsiveness, and enhanced hydraulic efficiency by eliminating the need for parasitic flow during re-pressurization and termination, while maintaining precise control and durability.
Implementation Method 1
a first resilient means configured to force said control valve member towards said seat so as to close said control valve
Implementation Method 2
main valve member being configured to be forced by pressure in said main control chamber towards said second seat so as to close an opening to said outlet
Implementation Method 3
said shuttle valve is configured such that the pressure in said shuttle control chamber tends to open the shuttle valve whereas the pressure in said main control chamber tends to close the shuttle valve
Data Source
AI summary
A flow control system for a fuel injector for an internal combustion engine is provided and includes an inlet port, an outlet, a return port, a 2-way control valve including a control valve member, a shuttle valve and a main valve. The control valve includes a first seat, a first resilient arrangement configured to force the control valve member towards the seat so as to close the control valve, and a first abutment that limits the lift of the control valve member away from the first seat. The first seat of the control valve is slidably arranged in the shuttle control chamber. An end stop for the first seat is provided such that the pressure in a shuttle control chamber tends to move the first seat towards the end stop. The first seat, upon its mechanical contact with a valve member is able to transmit at least a part of the force of the resilient means onto a shuttle valve body in the opening direction of the shuttle valve.