Fuel Distributor Holder Reducing Stress Peaks via Segmented Enclosure
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Solution Overview
Problem
The existing methods for mounting fuel distributor rails on internal combustion engines face issues such as tension peaks due to notches, complex geometry requirements, high residual stresses, and poor controllability of soldering processes, leading to increased costs and potential flaws in the final connection.
Innovation Solution
A holder system with a connection element that encloses the tubular base element by 360 degrees, featuring bendable connection arms and a deformable ring for improved stability and reduced stress peaks, allowing for easier assembly and reduced soldering surface area, which enhances component rigidity and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional connection element with radial connection is used, then the component can be fastened to the engine, but tension peaks arise due to notches at the transition between connection element and tubular base element
Solution Approach 1:
The connection element is divided into multiple segments (first connection element and second connection element) that can be assembled separately. This segmentation eliminates the need for complex notching at transitions, thereby reducing stress peaks while maintaining connection strength.
Solution Approach 2:
Instead of creating a radial connection with notches at the transition zone, the invention inverts the approach by using longitudinal connections with circumferential engagement. The connection elements engage the tubular base element around its circumference, eliminating stress-concentrating notches.
2Ease of manufacture
If traditional radial connection geometry is used, then the component can be attached, but the individual components must be radially held in place during joining, which is especially critical for soldered connections
Solution Approach 1:
The connection transitions from radial positioning to longitudinal alignment. The connection elements are guided into place along the longitudinal axis of the tubular base element, eliminating the need for complex radial positioning and holding during the joining process.
3Ease of manufacture
If formed parts with high degree of reforming are used, then the connection element can be produced, but residual stresses are generated that may be unleashed by subsequent heat treatment, adversely affecting dimensional accuracy
Solution Approach 1:
The connection elements are designed as simple, easily replaceable components that can be produced through less severe forming processes. Their simplicity allows for production without excessive reforming, minimizing residual stresses while maintaining functional requirements.
4Ease of operation
If long bent parts are used for the connection element, then the holder can be assembled, but the parts are flexible in loading directions, resulting in low natural frequencies and high stressing
Solution Approach 1:
The connection element is segmented into multiple rigid sections (first and second connection elements) rather than a single long bent part. Each segment maintains rigidity while the overall assembly remains flexible enough for assembly operations.
Solution Approach 2:
The connection system combines rigid connection elements with the tubular base element to create a composite structure that provides both assembly flexibility and operational rigidity. The distributed connection points create a stiff overall structure despite individual element flexibility.
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 holder system reduces stress peaks and assembly complexity, improves component rigidity, and enhances the controllability of the soldering process, resulting in cost-effective and robust connections with minimized tolerance demands and reduced intrinsic stress.
Implementation Method 1
a notching effect and thus abrupt changes in the stress characteristic is/are able to be reduced
Implementation Method 2
featuring bendable connection arms and a deformable ring for improved stability
Implementation Method 3
a subsequent soldering process for the final connection
Data Source
AI summary
A holder is used for fastening a component, in particular a fuel distributor, to an internal combustion engine. The holder has at least one connection element, which includes a locating area. In the installed state, in which the connection element rests against an outer side of the component via its locating area, the locating area of the connection element extends across an angle greater than 180 degrees in relation to a longitudinal axis of the component. Furthermore, in the installed state, in which the connection element is resting via its locating area against the outer side of the component, the locating area has the form of a cylinder jacket. In addition, a system having a component and such a holder is provided.