Fuel Injection Valve Movable Core Boost Structure
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Solution Overview
Problem
Conventional fuel injection valves face challenges in opening against high fuel pressures due to increased valve closing forces, leading to variations in valve opening timing and fuel injection amounts, and require higher magnetic attraction forces which can be inefficient.
Innovation Solution
A fuel injection valve design incorporating a movable core with a core boost structure, where the movable core contacts the valve body at a predetermined distance to initiate opening, and a communication groove to reduce fuel compression and enhance movement, allowing for reduced magnetic attraction force and improved timing consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high fuel pressure is used, then fuel injection performance is improved, but valve closing force increases making valve opening difficult
Solution Approach 1:
The movable core is positioned at a predetermined distance from the valve body before actuation, creating a pre-compression state. When the coil is energized, the movable core travels this predetermined distance and contacts the valve body, delivering a concentrated impact force that efficiently overcomes the high valve closing force caused by high fuel pressure, enabling reliable valve opening without requiring excessively high magnetic attraction force.
Solution Approach 2:
A communication groove is provided in the movable core to allow fuel to flow from a high-pressure region to a low-pressure region. This reduces fuel compression and pressure buildup in the movable core during actuation, minimizing resistance to movement and allowing the movable core to reach the valve body more efficiently, thereby reducing the required magnetic attraction force while maintaining effective valve opening capability.
2Force
If large magnetic attraction force is used to open the valve, then valve opening capability is improved, but energy consumption increases
Solution Approach 1:
The movable core is pre-positioned at a predetermined distance from the valve body, creating a ready-to-actuate state. This allows the system to use a shorter, more efficient magnetic stroke to deliver the necessary impact force, reducing the energy required compared to systems that require longer magnetic attraction strokes or continuous high-force magnetic fields.
Solution Approach 2:
The system replaces a direct high-force magnetic attraction mechanism with a mechanical amplification approach. The movable core acts as a mechanical amplifier, converting a moderate magnetic attraction force applied over a predetermined distance into a high-impact contact force on the valve body, thereby achieving effective valve opening with lower energy consumption.
3Force
If movable core travels long distance to contact valve body, then valve opening force is improved, but valve opening timing variation increases
Solution Approach 1:
The movable core is precisely positioned at a predetermined distance from the valve body before each actuation cycle. This controlled initial position ensures consistent travel distance and contact timing, reducing variation in valve opening timing while maintaining the benefits of the impact-force opening mechanism.
Solution Approach 2:
The communication groove provides a pressure equalization path that reduces fuel compression effects on the movable core during travel. This minimizes variations in movement dynamics caused by fuel pressure fluctuations, leading to more consistent valve opening timing across different operating conditions.
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 design enables efficient valve opening under high fuel pressures with reduced magnetic attraction force, minimizing variations in valve opening timing and fuel injection amounts, while maintaining consistent fuel flow.
Implementation Method 1
a fixed core that generates a magnetic attraction force upon energization of a coil
Implementation Method 2
a spring member that is elastically deformed by the valve opening operation of the valve body and exerts a valve closing elastic force
Data Source
AI summary
A fuel injection valve includes a valve body, a fixed core, a movable core, a spring and a cup. The movable core has a first core contact surface which contacts the valve body when the movable core is moved by a predetermined distance away from a nozzle hole, and a second core contact surface which contacts the cup when the movable core is moved away from the nozzle hole. The movable core, the cup and the valve body form a fuel storage chamber which is surrounded by the movable core, the cup and the valve body to accumulate fuel. The first core contact surface is located inside the fuel storage chamber. The first core contact surface and the second core contact surface have a communication groove through which the inside and the outside of the fuel storage chamber communicate with each other.