Fuel Injection Assembly With Guides to Prevent Injector Distortion
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Solution Overview
Problem
Existing fuel injection systems face issues such as injector distortion during assembly, pressure loss of fuel, increased number of components, and amplified vibration and noise due to direct connection of the injector to the common rail without a fuel pipe, which complicates the assembly process and requires dedicated jigs or tools.
Innovation Solution
A fuel injection system with a bracket fixed to the cylinder head, a fuel accumulator supported by the bracket, and an injector directly connected to the accumulator, where at least one of the accumulator or the bracket has guide members to guide the injector to a mount position on the cylinder head, eliminating the need for dedicated jigs and tools, and incorporating a ladder or grid-shaped bracket for reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the injector is directly connected to the common rail without a fuel pipe, then the number of components is reduced and pressure loss is suppressed, but the injector may undergo distortion during assembly due to flexural loads
Solution Approach 1:
The patent introduces a bracket as an intermediary component between the common rail and the injector. The bracket includes a holding portion that holds the injector in a predetermined position, preventing flexural loads during assembly while maintaining the direct connection structure. This mediator resolves the contradiction by providing mechanical support without adding a fuel pipe.
2Strength
If the common rail is fixed to the head cover via mounting portions, then the common rail structure becomes more complex and larger, but the fixing strength is improved
Solution Approach 1:
The patent segments the fixing function from the common rail body by introducing a separate bracket component. The bracket includes fixing portions that engage with the head cover and a holding portion for the injector, separating the mounting function from the fuel accumulation function. This reduces the complexity of the common rail structure while maintaining fixing strength.
3Quantity of substance
If no bracket is used for fixing the common rail, then the number of components is reduced, but a separate bracket becomes necessary for fixing the common rail to the head cover
Solution Approach 1:
The patent merges the functions of common rail mounting and injector positioning into a single bracket component. The bracket includes both fixing portions for attaching to the head cover and a holding portion for the injector, combining multiple functions into one component to avoid increasing the number of parts while maintaining necessary fixing strength.
4Manufacturing precision
If dedicated jigs or special tools are used to mount the injector, then the injector positioning precision is improved, but the assembly process complexity increases and additional tools are required for maintenance
Solution Approach 1:
The patent implements self-service positioning where the bracket's holding portion automatically maintains the injector in the predetermined position during assembly. The guide portions on the cylinder head work with the bracket to self-align and position the injector correctly without requiring external jigs or special tools, simplifying the assembly process while maintaining precision.
Data Source
AI summary
An object of the present invention is to provide a fuel injection system capable of suppressing an occurrence of distortion in an injector during assembly of components. A fuel injection system (3) includes: a bracket (5) which is fixed to a cylinder head (21) of an engine (2); a fuel accumulator (6) which is supported by and fixed to the bracket (5) and which accumulates pressure of fuel supplied from a fuel pump; and an injector (7) which is directly connected to the fuel accumulator (6) and mounted to the cylinder head (21) and which injects the fuel, supplied from the fuel accumulator (6), into a combustion chamber. At least one of the fuel accumulator (6) and the bracket (5) has guide members (64, 513) which guide the injector (7) to a mount position on the cylinder head (21).