Fuel Distributor Rail Segmentation for Cost Reduction
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Solution Overview
Problem
The high cost and complexity of manufacturing fuel distributor rails for gasoline engines arise from the need for deep drill holes in steel components, which require stringent tolerance control, increasing manufacturing expenses.
Innovation Solution
Decoupling the fuel channel and connecting pieces allows for the creation of outlet openings on the main tube during an initial drilling step, with connecting pieces attached later via material bonding, such as soldering or brazing, reducing the need for deep drilling and lowering tolerance requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If deep drill holes are created in steel connecting pieces to manufacture connecting channels, then the structural integrity and fluidic connection are ensured, but the manufacturing cost increases due to high tolerance requirements
Solution Approach 1:
The fuel distributor rail is divided into separate components: a main tube with outlet openings and separate connecting pieces with connecting channels. These components are manufactured independently and then joined together, allowing each part to be optimized for its specific function and manufactured more easily without requiring deep drill holes through the entire assembly.
Solution Approach 2:
The main tube is prepared in advance with outlet openings created by simple drilling through the wall thickness. The connecting pieces are also pre-manufactured with their channels. These preliminary preparations eliminate the need for subsequent deep drilling operations, reducing manufacturing complexity and cost.
2Device complexity
If deep drill holes are created for connecting channels, then the connecting pieces can be integrated into the main tube, but the manufacturing process becomes more complex due to stringent tolerance control requirements
Solution Approach 1:
By segmenting the fuel distributor rail into a main tube and separate connecting pieces, the patent avoids the need for deep drill holes that would require stringent tolerance control. Each component can be manufactured with more relaxed tolerances and then assembled together.
Solution Approach 2:
The patent changes the drilling parameters by creating only shallow outlet openings in the main tube wall rather than deep drill holes through the entire connecting piece. This parameter change from deep to shallow drilling significantly reduces the manufacturing precision requirements while still achieving the desired fluidic connection.
3Strength
If connecting pieces are made with minimum length requirements, then the structural strength is maintained, but deep drill holes are required increasing manufacturing expenses
Solution Approach 1:
The connecting function is segmented into separate connecting pieces that are attached to the main tube. These connecting pieces can be optimized for strength with their own channel designs, while the main tube only requires shallow outlet openings, avoiding the need for expensive deep drilling operations.
Solution Approach 2:
The connecting pieces are pre-manufactured with their channels and then attached to the main tube. This preliminary manufacturing allows the use of shorter, stronger connecting pieces without requiring deep drill holes, thereby reducing manufacturing expenses while maintaining structural strength.
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 approach significantly reduces manufacturing costs by simplifying the drilling process and lowering tolerance requirements for the connecting channels, while maintaining the structural integrity and fluidic connection necessary for efficient fuel distribution.
Implementation Method 1
the connecting element is connected to the main tube in a material bonded manner, preferentially by soldering or brazing
Implementation Method 2
the connecting element is connected to the main tube in a material bonded manner, preferentially by soldering or brazing
Data Source
AI summary
A fuel distributor rail for a fuel injection system for an internal combustion engine in motor vehicles, in particular for gasoline engines. The fuel distributor rail comprises a main tube, wherein the main tube has a fuel channel extending in the longitudinal direction of the main tube. The main tube comprises at least two outlet openings, wherein the outlet openings branch off the fuel channel. A connecting element is arranged on the main tube, wherein the connecting element has an attachment wall that rests against the main tube. The connecting element is connected to the main tube in a material bonded manner and comprises at least two connecting pieces. The connecting pieces have a connecting channel each for the fluidic connection of an outlet opening to each injection nozzle.