Fluid Valve Assembly with Rounded Edges and Dual Springs
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Solution Overview
Problem
Fuel pressure pulsations in direct injection engines cause noise, vibration, and cavitation due to the operation of metallic outlet check valves and sharp edges in fuel pump housings, leading to audible noise at low engine speeds.
Innovation Solution
A fluid valve assembly with a movable outlet check valve featuring a protrusion within the valve seat, a main spring for closure, and a secondary spring to prevent contact with the seat, combined with rounded edges to reduce cavitation, minimizing noise and vibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic outlet check valve is used for durability, then the valve can withstand high fuel pressure, but the repeated impact of the valve against the valve seat creates audible clicking noise
Solution Approach 1:
The valve seat and valve protrusion are designed with rounded surfaces instead of sharp edges. This curvature prevents the valve from impacting the seat with high force during closure, eliminating the clicking noise while maintaining the metallic valve's durability and pressure withstanding capability.
Solution Approach 2:
The compression spring is positioned to cushion the valve before it contacts the valve seat. The spring absorbs the impact energy gradually, preventing direct high-force impact between the metallic valve and seat, thereby eliminating noise while preserving valve strength and sealing function.
2Ease of manufacture
If the fuel pump housing is constructed with a sharp edge at the outlet port, then the housing structure is simple and strong, but the rapid flow of fuel past the sharp edge creates cavitation and noise
Solution Approach 1:
The outlet port in the fuel pump housing is designed with a rounded edge instead of a sharp edge. This curvature allows fuel to flow smoothly without creating the low-pressure zones that cause cavitation, eliminating noise while maintaining structural simplicity and manufacturing ease.
3Reliability
If the outlet check valve closes directly against the valve seat, then the valve provides effective sealing, but the direct impact creates vibration and noise
Solution Approach 1:
The compression spring is positioned between the valve and the housing to cushion the valve before it contacts the valve seat. This gradual deceleration eliminates direct impact, reducing vibration and noise while maintaining reliable sealing through the rounded contact surfaces.
Solution Approach 2:
The rounded surfaces of the valve protrusion and valve seat ensure gradual contact during closure, distributing the sealing force over a larger area and reducing impact stress. This maintains sealing effectiveness while minimizing vibration and noise from direct impact.
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 solution effectively eliminates noise and vibration by preventing valve impact and reducing cavitation, while maintaining fluid flow without sharp edges, resulting in a quieter and more efficient fuel delivery system.
Implementation Method 1
a compression spring which stores and releases mechanical energy in order to urge the outlet valve between its open and closed positions
Implementation Method 2
the rapid flow of the fuel past the sharp edge of the port creates cavitation in the fuel which, in turn, creates noise
Data Source
AI summary
A fluid valve assembly having a housing with a valve seat which forms a fluid port. A valve is movable along an axis relative to the port between an open and a closed position. This valve includes a protrusion complementary in shape to, but slightly smaller than, the port. The protrusion is at least partially positioned in the port when the valve is in its closed position at which time a clearance space between the port and the protrusion is sufficiently small to prevent fluid flow through the port. A main spring disposed between the housing and the valve resiliently urges the valve towards its closed position. A second spring is also operatively positioned between the valve and the housing which urges the valve away from the valve seat towards its open position and prevents contact between the valve and the valve seat.