Fuel Injection Assembly Tab Pocket Rotational Alignment
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Solution Overview
Problem
Existing fuel injection assemblies face challenges in achieving precise rotational alignment and cost-effective assembly while minimizing production and mounting tolerances, and in providing a space-saving configuration that avoids mechanical weaknesses and assembly complexities.
Innovation Solution
A fuel injection assembly design featuring a metallic fuel injector with a recessed inlet port and a plastic injector cup having a tab and pocket configuration, which allows for precise indexing and axial displacement, along with a spring clip for preload, enabling easy assembly and robust mechanical design without additional intervening parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a traditional fuel injector connection system is used, then the assembly process is simple, but precise rotational alignment and minimizing production and mounting tolerances cannot be achieved
Solution Approach 1:
The patent employs asymmetric geometric features including a non-circular tab shape with specific curvature radii and a corresponding asymmetric pocket structure. These asymmetric designs provide inherent rotational positioning that achieves precise rotational alignment without requiring complex alignment procedures or additional positioning components.
Solution Approach 2:
The tab is received within the pocket, creating a nested configuration where the smaller tab feature is positioned within the larger pocket structure. This nesting arrangement provides both rotational alignment through the asymmetric geometry and mechanical retention, achieving precise positioning while maintaining assembly simplicity.
2Manufacturing precision
If additional intervention parts are added to achieve precise alignment, then manufacturing precision improves, but assembly complexity and production costs increase
Solution Approach 1:
The patent merges the alignment function and retention function into a single integrated tab-pocket structure. The asymmetric geometry of the tab and pocket simultaneously provides rotational positioning and mechanical retention, eliminating the need for separate alignment marks, positioning pins, or additional intervention parts that would increase assembly complexity.
3Volume of moving object
If a compact configuration is used to save space, then the assembly size is reduced, but mechanical weaknesses and assembly complexities may arise
Solution Approach 1:
The patent applies local quality by concentrating the alignment and retention functions in specific localized features (the tab and pocket) rather than distributing complexity throughout the entire assembly. This allows for a compact overall configuration while maintaining mechanical strength through the optimized geometry of the critical alignment features.
Data Source
AI summary
The present disclosure relates in general to injectors and, more specifically, to a fuel injection assembly that may be used in an internal combustion engine. In some embodiments, a fuel injection assembly may include: a fuel injector with a fuel inlet port and a fuel outlet end; and an injector cup with a recess receiving the fuel inlet port of the fuel injector through an opening of the recess. The injector cup comprises a collar extending circumferentially around the opening. The injector cup comprises a tab extending longitudinally beyond the opening in a direction towards the fuel outlet end. The tab projects axially beyond the collar in a longitudinal direction towards the fuel outlet end. The fuel injector comprises a pocket receiving the tab.