Fuel Distributor Mounting Supports via Soldered Sheet-Metal Brackets
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Solution Overview
Problem
Existing fuel distributors with forged pressure accumulator rails require costly material removal processes for machining and have weight and machining efficiency issues due to complex mounting support structures.
Innovation Solution
A fuel distributor with a forged stainless steel alloy tubular base body and integral injector receivers, where mounting supports are formed as sheet-metal brackets joined by substance bonding, reducing material removal needs and improving machining properties through furnace soldering and heat treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mounting supports are formed by forging or integral machining from the base body, then mechanical strength is improved, but weight increases and machining complexity increases
Solution Approach 1:
The mounting supports are separated from the base body and produced as independent sheet-metal formed parts. This segmentation allows the base body to be optimized for strength while the mounting supports can be made from lighter sheet metal, reducing overall weight while maintaining mechanical strength through the bonding connection.
Solution Approach 2:
The patent combines the forged base body with sheet-metal formed mounting supports using substance bonding (soldering). This composite construction allows each component to be made from the most suitable material and process for its function, achieving both strength and weight reduction.
2Stability of the object's composition
If mounting supports are formed by forging or integral machining, then structural integrity is improved, but manufacturing cost increases due to material removal processes
Solution Approach 1:
By separating the mounting supports from the base body, the patent eliminates the need for costly material removal processes on the forged base body. The sheet-metal formed supports can be produced more economically through forming operations rather than machining.
Solution Approach 2:
The patent replaces mechanical machining processes with substance bonding (soldering) to join the mounting supports to the base body. This substitution eliminates material removal and reduces manufacturing complexity and cost.
3Strength
If the base body is forged with integral mounting supports, then mechanical strength is improved, but machining requirements increase due to deep hole drilling and material removal
Solution Approach 1:
The patent divides the pressure accumulator rail into a forged base body and separate sheet-metal mounting supports. This segmentation eliminates the need for complex machining operations on the base body, as the mounting supports are attached separately through substance bonding rather than being machined from the base material.
4Weight of moving object
If sheet-metal formed mounting supports are used, then weight is reduced and machining requirements are decreased, but joining complexity increases due to substance bonding process
Solution Approach 1:
The patent replaces mechanical joining methods (such as riveting or bolting) with substance bonding (soldering) to join the sheet-metal mounting supports to the forged base body. This provides a permanent, strong joint that simplifies the overall assembly while maintaining the weight advantages of sheet-metal supports.
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 results in a lightweight fuel distributor with reduced material removal requirements, enhanced mechanical strength, and improved corrosion resistance, while minimizing tool wear and eliminating the need for pickling and passivation processes.
Implementation Method 1
The mounting supports are produced separately by sheet-metal forming and are joined to the base body of the pressure accumulator rail by substance bonding
Implementation Method 2
improving machining properties through furnace soldering and heat treatment
Data Source
AI summary
A fuel distributor which has a pressure accumulator rail for receiving pressurized fuel. The pressure accumulator rail has a forged base body. Mounting supports are joined to the base body by substance bonding. A mounting support is formed by two metal brackets each configured as a sheet-metal formed part. Each metal bracket has a holding portion adapted to the outer contour of the base body, a leg angled relative to the holding portion, and a mounting flange on the free end of the leg and angled away therefrom. A length portion of the base body is received between the holding portions. The holding portions partially surround the base body. The base body and the holding portions are joined by substance bonding. The legs of the two metal brackets lie next to each other at least in regions and are also joined together by substance bonding.